Bard DC3002 User Manual

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INSTALLATION INSTRUCTIONS & REPLACEMENT PARTS LIST

DC3002 and DC3003 SOLID STATE LEAD/LAG CONTROLLER

with DC FAN CONTROL

Bard Manufacturing Company, Inc.

Manual No.:

2100-484E

Bryan, Ohio 43506

Supersedes:

2100-484D

Since 1914...Moving ahead, just as planned.

File:

Vol. III Tab 19

Date:

08-29-11

 

 

Manual

2100-484E

 

 

Page

1 of 22

 

CONTENTS

Getting Other Information and Publications

3

DC3000 General Information

 

Shipping Damage ..................................................

4

General ..................................................................

4

Theory of Operation ...............................................

4

Controller Certifications .........................................

4

Specifications/Features for Basic Controller

 

DC3000 Basic Controller .......................................

5

Mounting the Controller

 

Installation Instructions ..........................................

5

Temperature Sensors

 

Remote Indoor Sensor ...........................................

5

Remote Outdoor Sensor ........................................

5

Temperature Sensor Logic

 

Using Multiple Sensors ..........................................

5

Controller Input/Output Specifications

 

Main Controller Board ............................................

6

Internal Alarm Board ..............................................

6

Low Voltage Field Wiring

 

Circuitry in the DC3000 ..........................................

7

Controller Grounding

 

Earth ground ..........................................................

7

Controller Power-Up

 

Time Delay on Power-Up .......................................

7

Fire Suppression Circuit

 

Disabling the DC3000 ............................................

7

Staging Delay Periods

 

Stages 1 - 4 ............................................................

7

Blower Operation

 

Various Blower Options .........................................

7

Advance (Swap) Lead/Lag Unit Feature

 

Manual Switching of Units .....................................

7

Accelerate Timer Feature

 

Testing the Timer Function .....................................

7

Humidity Control Option

 

Adding Optional Humidity Control ..........................

8

Sequence of Operation - Cooling (Air Conditioners)

No Economizer ......................................................

8

With Economizers ..................................................

8

Sequence of Operation - Heating (Air Conditioners)

With Electric Heat ..................................................

9

Security (Locking) Feature

 

 

Locking and Unlocking the DC3000 ......................

 

9

Generator Run Feature

 

 

Standby Generator Disable Operation ...................

 

9

Backup DC Power Connection

 

 

Input Connections Available ..................................

 

9

DC Fan Control

 

 

Free Cooling & Emergency Ventilation ................

 

10

Shelter Purge Control ..........................................

 

10

Controller Wiring

 

 

Refer to Connection Diagram ......................

10 & 11

Alarm Wiring

 

 

Wiring Alarm Relays ............................................

 

16

2nd Stage Cooling Alarm

 

 

Alarm Output is Available .....................................

 

16

Refrigerant Pressure Alarms

 

 

Connecting the Alarm Circuit ...............................

 

16

Emergency Ventilation Sequence

 

 

Using Economizers

 

 

Two Operating Sequences ..................................

 

16

Programming Instructions ...................................

 

19

Figures

 

 

 

Figure 1 DC3002 Controller Connections for 2 Air

 

 

Conditioners with Economizer ...................

 

11

Figure 2 DC3002 Controller Connections for 2 Air

 

 

Conditioners with No Economizer ..............

 

12

Figure 3 DC3003 Controller Connections for 3 Air

 

 

Conditioners with 3 Economizers ..............

 

13

Figure 4 DC3003 Controller Connections for 3 Air

 

 

Conditioners with Economizers

 

 

 

(No Economizer A/C #3).........................

 

14

Figure 5 DC3003 Controller Connections for 3 Air

 

 

Conditioners with No Economizers ............

 

15

Figure 6 Alarm Board Connections for Normally Closed

 

“NC” Open-On-AlarmStrategy ...................

 

17

Figure 7 Alarm Board Connections for Normally

 

 

Open “NO” Close-On-AlarmStrategy .....

18

(Label)

DC3000 Series .......................................

 

20

Figure 8 Parts List Description .............................

 

21

Tables

 

 

 

Table 1 Controller Connection Diagrams ............

 

10

Table 2

Parts List ................................................

 

22

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Getting Other Information and Publications

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

Standard for the Installation ..............

ANSI/NFPA 90A

of Air Conditioning and

 

Ventilating Systems

 

Standard for Warm Air Heating ........

ANSI/NFPA 90B

and Air Conditioning Systems

 

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA

Air Conditioning Contractors of America

 

1712 New Hampshire Avenue, NW

 

Washington, DC 20009

 

Telephone: (202) 483-9370

 

Fax: (202) 234-4721

ANSI

American National Standards Institute

 

11 West Street, 13th Floor

 

New York, NY 10036

 

Telephone: (212) 642-4900

 

Fax: (212) 302-1286

ASHRAE

American Society of Heating, Refrigerating,

 

and Air Conditioning Engineers, Inc.

 

1791 Tullie Circle, N.E.

 

Atlanta, GA 30329-2305

 

Telephone: (404) 636-8400

 

Fax: (404) 321-5478

BARD

Bard Manufacturing Company, Inc.

 

1914 Randolph Drive

 

Bryan, OH 43506

 

Telephone: (419) 636-1194

 

Fax: (419) 636-2640

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** IMPORTANT **

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. Please read entire manual before proceeding.

SHIPPING DAMAGE

Upon receipt of equipment, the carton 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.

GENERAL

NOTE: DC3000 is used throughout this Manual as a general reference to the controller system. There are two controller models, DC3002 for 2 HVAC units and DC3003 for 3 HVAC units, and these model numbers are referenced when specific features or characteristics apply only to either the DC3002 or the DC3003. Occasional reference is made to alarm board AB3002 or AB3003. AB3002 is the internal alarm board for the DC3002 controller, and AB3003 is the internal alarm board for the DC3003 controller.

These instructions explain the operation, installation and troubleshooting of the DC3000 controller.

All internal wiring is complete. Only attach low voltage field wiring to designated terminal strips.

The DC3000 is for use with units with or without economizers, and has a dehumidification control feature if an optional humidity controller is connected.

Each unit should be sized to handle the total load of the structure if 100% redundancy is required.

It is recommended that a five (5) minute compressor time delay relay be installed in each unit.

The DC3000 controllers are suitable for both 50 and 60 HZ operation, and are fully configurable such that they can be used in virtually any installation. See Controller Programmable Features and Default Settings.

THEORY OF OPERATION

The DC3002 controller is used to control two wall mount air conditioners from one control system. It provides total redundancy for the structure and equal wear on both units. It can be used with units with or without economizers and it is recommended that both units be equipped alike.

The DC3003 controller is designed to control 3 air conditioners, and can be used for 2 if it is anticipated the third unit may be installed later.

NOTE: If this is done, see Note 1 on Alarm Board Connections (Figure 6 or 7) to prevent nuisance Power Loss Alarm indication for absent HVAC #3

When DC3003 is used for controlling three HVAC units, only units 1 or 2 operate in lead/lag sequence. HVAC #3 is always last to operate and functions only in the number 3 position. All three units are available to operate on-demandas required.

Alarm capability is standard on both models.

CONTROLLER CERTIFICATIONS

The DC3000 main controller board, optional alarm boards, and remote sensors have undergone extensive testing for immunity and emissions. This system is FCC-compliant,in accordance with CE requirements, and meets the following standards:

EN50082-2Standard for Immunity

EN55011 Standard for Emissions

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SPECIFICATIONS/FEATURES FOR BASIC CONTROLLER

DC3000 Basic Controller

•Input power: 18 to 32VAC, 60/50Hz, power is supplied from A/C #1 and/or A/C #2

•Isolation circuitry: no line or low voltage phasing required

•Backup power: connection for -24VDCor-48VDC(-20to-56V)maintains microprocessor operation, front panel indication, and alarm relay operation during commercial power outages.

•Digital display: 4-characterLCD •Temperature display: F or C

•HVAC outputs: Form A (NO) relays (1A @ 24VAC) •Cooling control stages: 2 for each A/C unit •Heating Control stages: 1 for each A/C unit •Dehumidification circuit: requires optional humidity controller as input signal.

•Operating temperature range: 0 to 120F (-18to 49C) •Storage temperature range:-20to 140F(-29to 60C) •Temperature accuracy: +/- 1F from60-85F(16-30C)

+/- 1% outside 60-85F•Lead/lag changeover time: 0 to 30 days •Timing accuracy: +/- 1%

•Inter-stagetime delay: 10 seconds between stages•Inter-stagedifferential: 2F (1C) for all modes•On-Offdifferential: 2F (1C) is standard, 4F (3C) when “excessive cycling” mode is enabled.

•Cooling set point range: 65 to 90F (18 to 32C) •Comfort setting-Cooling72F (22C), Heating 68F(20C), for 1 hour.

•Dead band (difference between cooling and heating set points): 2F to 20F (1C to 10C)

•Fire/smoke interface: standard NC circuit jumper, remove for connection to building system control, shuts down both A/C units immediately.

•Memory: EEPROM for set point and changeable parameters (maintains settings on power loss). •Temperature sensors: 1 local is standard, will accept up to 2 optional 25-footremote sensors, Bard part number8612-023.One can be used for remote indoor sensor and one is dedicated for outdoor sensor for DC Fan free cooling operation, if desired.

•Controller Enclosure: 20-gaugepre-paintedsteel, 9.25"W x 13.50"H x 3.00"D, hinged cover, thirteen (13) .875" diameter electrical knockouts.

•LEDs for basic controller: Lead unit, Cooling stages 1 through 4, Heating Stages 1 through 4, Dehumidification operation. DC3003 has cooling stage and alarm LED’s displayed internally for HVAC #3.

•Six (6) Push-buttoncontrols: On/Offswitch-Changeleadunit-Increaseand Decrease setpoints-Program/Save-Comfort.

MOUNTING THE CONTROLLER

Included in the controller carton is the controller and installation instructions.

The controller should be installed on a vertical wall approximately four (4) feet above the floor - away from drafts and outside doors or windows. Four (4) mounting holes are provided for mounting to the wall, and 7/8" holes for conduit connections are provided in both the base, sides and top of the controller.

TEMPERATURE SENSORS

The standard (local) temperature sensor has 12" leads and comes installed from the factory.

The controller is designed to accept 1 additional remote indoor sensor, and connects to “Rem 1”. The Bard part number for the optional sensor with 25-footleads is8612-023.This remote indoor sensor can be installed as required in the structure to address hot spots, barriers to airflow, etc. It can also be used as the local sensor

Outdoor sensor, same 8612-023with25-footleads, is required fornon-economizerinstallations when DC fan is to be used for free cooling. This sensor connects to the “Out” terminals.

It is recommended that the sensor lead wires be installed in conduit for protective purposes.

The highest reading of any connected indoor sensor will be used for high temperature alarm and the lowest reading sensor will be used for low temperature alarm.

NOTE: All sensors are polarity sensitive. The copper lead must connect to terminal CU, and the silver lead to AG.

Sensors are solid state, not RTD.

Use only sensors supplied by Bard.

TEMPERATURE SENSOR LOGIC

The standard local (Loc) sensor monitors the temperature at the controller location. If this is the only sensor connected, it will control the temperature read-out,the space (building) temperature, and also be used for Low and High Temperature alarm functions.

If one REMOTE sensor is installed and connected (Rem 1), the temperature read-outwill display and the building will be controlled to anaverage of connected sensors. If there is more than 10F difference from the highest to the lowest connected sensor, the actual control will be governed by the hottest sensor for cooling and the coldest sensor for heating.

If two indoor temperature sensors are used, the average of the two sensors becomes the controller cooling and testing set point.

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CONTROLLER INPUT/OUTPUT SPECIFICATIONS

DC3002/3003 CONTROLLER CONNECTIONS

Located on Main Controller Board

Unit #1

 

C – 24VAC common

 

 

 

R – 24VAC hot

 

 

 

G – fan (Form A, NO)

 

 

 

Y1 – 1st-stagecool (Form A, NO)

 

 

Y2 – 2nd-stagecool (Form A, NO)

 

 

W – heat (Form A, NO)

 

Unit #2

 

C – 24VAC common

 

 

 

R – 24VAC hot

 

 

 

G – fan (Form A, NO)

 

 

 

Y1 – 1st-stagecool (Form A, NO)

 

 

Y2 – 2nd-stagecool (Form A, NO)

 

 

W – heat (Form A, NO)

 

Unit #3

 

C – 24VAC common

 

(DC3003 only

R – 24VAC hot

 

and located on

G – fan (Form A, NO)

 

InternalAlarm

Y1 – 1st-stagecool (Form A, NO)

Board)

 

Y2 – 2nd-stagecool (Form A, NO)

 

 

W – heat (Form A, NO)

 

F1-F2

Fire/smoke interface

 

 

Shipped with jumper installed (a)

 

48Vdc

Back-uppower input

 

 

-24Vdcor–48Vdc

 

 

-20Vto–56Vrange

 

Local

Main sensor, 12-inchleads

 

NOTE:

 

CU – copper, AG – silver

 

 

 

Polarity sensitive

Sensors are

Rem 1

Optional remote indoor sensor

solid state,

 

CU – copper, AG – silver

 

not RTD.

 

Polarity sensitive

 

 

Out

Optional outdoor sensor (b)

Use Bard

 

CU – copper, AG – silver

sensors only.

 

Polarity sensitive

 

 

 

Gen

Generator interface G1-G2

 

 

Shipped with jumper installed (a)

 

H1-H2

Humidity controller input

 

 

Requires optional controller

 

 

Field installed

 

(a)These connections require either jumper or Normally Closed (NC) relay contact at the Fire/Smoke and Generator interface for Controller to function.

(b)Required connection if field installed DC Fan is to be used for free cooling and no economizers are installed in HVAC units.

Note: All alarm relays are dry contacts rated 1A @ 24VAC, 120VAC or 150VDC.

DC3002/3003 CONTROLLER CONNECTIONS

Located on Internal Alarm Board AB3002

DC3002 Inputs

 

Lockout 1

2,3 – input from HVAC #1

Lockout 2

2, 3 – input from HVAC #2

Y Unit 1

signals when comp. #1 is active

Y Unit 2

signals when comp. #2 is active

DC3002 Alarm Outputs

Smoke/Fire

Form C (SPDT)

Lockout 1

Form C (SPDT)

 

Refrigerant alarm HVAC #1

Lockout 2

Form C (SPDT)

 

Refrigerant alarm HVAC #2

Power Loss 1

Form C (SPDT)

 

Power loss HVAC #1

Power Loss 2

Form C (SPDT)

 

Power loss HVAC #2

Low Temp

Form C (SPDT)

 

Low temperature alarm

High Temp 1

Form C (SPDT)

 

High temperature alarm #1

High Temp 2

Form C (SPDT)

 

High temperature alarm #2

Controller

Form C (SPDT)

 

Controller failure alarm

DC3002 Control Outputs

Econ 1

E, F - Form A (NO)

 

See note (c )

Econ 2

E, F - Form A (NO)

 

See note (c )

DC Fan

Form C (SPDT)

 

Pilot relay for DC Fan control

2nd Stage

Form C (SPDT)

 

2nd-stagecooling alarm

(c ) Make these connections to terminals E & F in HVAC 1 and 2 respectively if desired to have economizers open for emergency ventilation at High Temp Alarm #2 setpoint condition.

DC3003 Inputs

Everything from DC3002 plus:

Lockout 3

2,3 – input from HVAC #3

DC3003 Alarm Outputs (on AB3003 Internal Alarm Board)

Everything from DC3002 plus:

Lockout 3

Form C (SPDT)

 

Refrigerant alarm HVAC # 3

Power Loss 3

Form C (SPDT)

 

Power loss HVAC #3

DC3003 Control Outputs

Econ 3

E, F - Form A (NO)

 

See note (c )

Alarm relays can be wired for NO (close on alarm) or NC (open on alarm) strategy. Alarm relays can be used individually if there are enough available building alarm points, or can be arranged into smaller groups or even a single group so that all alarm capabilities can be utilized. When multiple alarms are grouped together and issued as a single alarm there will be no off-siteindication of which specific problem may have occurred, only that one of the alarms in the group has been triggered. The individual alarm problem will be displayed on the LED display on face of the controller.

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LOW VOLTAGE FIELD WIRING

The DC3000 is powered from the air conditioners that it is controlling, 24VAC (18-32V)low voltage only.

Circuitry in the DC3000 isolates the power supplies of all connected air conditioners so that no back feeds or phasing problems can occur. Additionally, if any air conditioner loses power, the DC3000 and the other air conditioner are unaffected and will continue to operate normally.

Connect the low voltage field wiring from each unit per the low voltage field wiring diagrams in Section on “Controller Wiring”.

CONTROLLER GROUNDING

A reliable earth ground must be connected in addition to any grounding from conduit.

CONTROLLER POWER-UP

Whenever power is first applied to the controller, there is a twenty (20) second time-delayprior to any function (other than display) becoming active. Thistime-delayis in effect if the controller On/Off button is used when 24VAC from air conditioners is present, and also if controller is in “ON” position and 24VAC from all connected air conditioners is removed and then restored.

FIRE SUPPRESSION CIRCUIT

To disable the DC3000 and shut down both air conditioners, terminals F1 and F2 may be used. The F1 and F2 terminals must be jumpered together for normal operation. A normally closed (nc) set of dry contacts may be connected across the terminals and the factory jumper removed for use with a field-installedfire suppression system. The contacts must open if a fire is detected. See appropriate connection diagram - Figures 1, 2 or 3 for this connection. Contacts should be rated for pilot duty operation at 2 amp 24VAC minimum. Shielded wire(22-gaugeminimum) must be used, and the shield must be grounded to the controller enclosure.

IMPORTANT NOTE: Some Bard models employ an electronic blower control that has a 60-secondbloweroff-delay.In order to have immediate shutdown of the blower motor, in addition to disabling the run function of the air conditioners will require a simple wiring modification at the blower control located in the electrical control panel of the air conditioners being controlled by the lead/lag controller. To eliminate the60-secondbloweroff-delay,disconnect and isolate the wire that isfactory-connectedto the “R” terminal on the electronic blower control, and then connect a jumper from the “G” terminal on the blower control to the “R” terminal on the blower control. The electronic blower control will now function as anon-offrelay with no offdelay, and the blower motor will stop running immediately when theF1-F2fire suppression circuit is activated (opened).

STAGING DELAY PERIODS

The following delays are built in for both cooling and heating:

Stage 1 – 0 seconds for blower (if not already on as continuous)

10 seconds for cooling or heating output

Stage 2 – 10 seconds after Stage 1 for blower

10 additional seconds for cooling or heating output

Stage 3 – 10 seconds after Stage 2

Stage 4 – 10 seconds after Stage 3

Note: For cooling Stages 1 and 2, the stage LED will blink for 10 seconds while the cooling output is delayed after that stage is called for. There is also a delay after the stage is satisfied, and after the LED stops blinking, the stage will turn off. There is a minimum 10-seconddelay between stages 2 & 3, and 3 & 4, but no delayed output when stage is turned on or off, and LED for those stages will not blink.

BLOWER OPERATION

The controller can be configured to have main HVAC blowers cycle on and off on demand; have all blowers run continuously (for DC3003, the blower is not “On” continuously for HVAC #3, but runs on demand only condition); or have the lead unit blower run continuously with the lag unit blower cycling on demand. Lead unit blower operating continuously is the default setting. There is also an option to have all blowers cycle on if one remote sensor is connected, and a temperature difference of more than 5F between any two sensors is observed. This helps to redistribute the heat load within the structure and should reduce compressor operating time.

When any of the stages are satisfied, the stage LED will blink for ten (10) seconds before the stage is actually turned off.

ADVANCE (SWAP) LEAD/LAG UNIT FEATURE

Pressing the Advance button for one (1) second will cause the lead and lag units to change positions. This may be useful during service and maintenance procedures.

Note: DC3003 always operates HVAC #3 in last position: only HVAC #1 and #2 operate in lead/lag sequence.

ACCELERATE TIMER FEATURE

Pressing the UP arrow button for five (5) seconds will activate an accelerate (speed-up)mode, causing the normal changeover time increments of days to be reduced to seconds. Example: 7 days becomes 7 seconds. When “ACC” displays, release button. Whichever LED is on, indicating lead unit will blink over for each second until the controller switches. This is a check for the timer functionality.

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HUMIDITY CONTROL OPTION

Note: This function is not available if controller is configured for heat pump.

The standard air conditioning system can be adapted to perform dehumidification control by addition of a simple humidity controller that closes-on-rise,and is connected to terminals H1 and H2 on the main controller board. Recommended Bard part number is8403-038(H600A 1014). See appropriate connection diagram - Figures 1, 2 or 3 for this connection.

The humidity control logic needs to be enabled in the program menu. Go to HuLE in the Programming Menu and change from No to Yes. This permits the following sequence of operation:

1.Temperature control always has priority over dehumidification. If there is any stage of cooling demand active, the dehumidification sequence is locked out.

2.If all stages of cooling are satisfied, and relative humidity is above the set point of humidity controller:

a.The green “Dehumid. Operation” light will come on, and the lag unit compressor and blower will operate until the set point of humidity controller is satisfied (or cancelled by a call for cooling).

b.If the space temperature drops to 67F, the electric heater of the lead unit will cycle to help maintain building temperature. It will cycle off at 69F.

c.If space temperature drops to 64F, the Stage 2 Heating light will come on and the lag unit compressor operating for dehumidification mode will cycle off until the building temperature rises above 65F from 1st stage heat and building load. The green “Dehumid. Operation” light stays on during this sequence, and when Stage 2 Heating light is Off, the compressor is On. The electric heater in lag unit is locked out in dehumidification mode.

CAUTION

Humidity controller set point should be in 55-60%relative humidity area: Setting controller to lower settings will result in excessive operating time and operating costs for the electric reheat, and in extreme cases could cause evaporator (indoor) coilfreeze-upif there are periods of light internal equipment (heat) loading.

SEQUENCE OF OPERATION – COOLING AIR CONDITIONERS – (NO ECONOMIZER)

First stage cooling set point is the setting (SP) input into the controller. Factory default is 75F/24C. At Stage 1 cooling SP, the blower of the lead unit will come on (if not already operating because of continuous fan selection for lead unit). The DC fan will also operate at this time if controller is configured for free cooling using DC fan, and if outdoor temperature is 1F or more below (dFon) setting for DC fan operation 50, 55 or 60F (default is 55). DC fan is off at 1F above the (dFon) setting.

At Stage 2 cooling call (SP + 2F), the compressor for lead unit comes on.

At Stage 3 cooling call (SP + 4F), the blower for the lag unit comes on, followed 10 seconds later by the compressor for the lag unit.

SEQUENCE OF OPERATION – COOLING AIR CONDITIONERS – (WITH ECONOMIZERS)

Note: Economizer Logic Enabled must be switched from No to Yes in the Programming Menu.

First stage cooling set point is the setting (SP) input into the controller. Factory default is 75F/24C. On a call for 1st Stage cooling, the blower will come on immediately (if not already on - See Blower Operation), and the Stage 1 LED will blink for 10 seconds before going solid, at which time the cooling output turns on. If the outdoor temperature and humidity conditions are below the set point of the economizer enthalpy control, the economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling, the compressor will automatically operate instead of the economizer.

Stage 2 cooling is 2F (1C) warmer than Stage 1. On a call for 2nd Stage cooling, the blower of the lag unit is turned on, and the Stage LED will blink for 10 seconds before going solid, at which time either the economizer or the compressor will turn on - based on enthalpy control setting and outdoor conditions.

Stage 3 cooling is 2F (1C) warmer than Stage 2. On a call for Stage 3 cooling, a signal is input into the lead unit economizer to cancel economizer and force lead unit compressor on. Stage 3 LED comes on solid with no blinking.

Stage 4 cooling is 2F (1C) warmer than Stage 3. If the lead unit compressor and lag unit economizer cooling capacity are not sufficient to hold the building temperature, and Stage 4 calls for cooling, a signal is input into the lag unit economizer to cancel economizer and force the lag unit compressor on. Stage 4 LED comes on solid with no blinking.

When any of the four (4) Stages are satisfied, the stage LED will blink for 10 seconds before the stage is actually turned off.

DC3003 only: Stage 5 cooling is 1F warmer than Stage 4. Stage 5 LED is located on the alarm board mounted inside the controller, and is marked Y1. There is also a Y2 LED, and Y1 and Y2 will cycle together.

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SEQUENCE OF OPERATION – HEATING (AIR CONDITIONERS W/ELECTRIC HEAT)

First stage heating set point is the dead band setting below first stage cooling set point (the SP entered into the program). The dead band is adjustable from 2-20F(1-10C),and the factory default is 10F (5C).

Second stage heating set point is 2F (1C) cooler than Stage 1.

DC3003 only: Stage 3 heat is the electric heater in HVAC #3.

SECURITY (LOCKING) FEATURE

The DC3000 controller can be locked such that unauthorized persons cannot make any changes to temperature set points or any other selectable parameters of the controller system.

The ON/OFF and Comfort buttons remain fully active for their normal intent. The Advance/Change/Save button remains active for the Advance feature only, which allows the position of the lead and lag air conditioners to be swapped (reversed). The Program button remains partially active - allowing the review of temperature sensor(s) actual reading of temperature, and the current settings/choices that have been chosen. However, no changes can be made when the controller is locked, and if the change button is pressed when in the Program mode, the display will come up showing “Locd” instead of flashing the selectable choices for that parameter. The default (DEF) reset capability is also disabled when the controller is in locked mode.

Locking and Unlocking the DC3000 Controller:

1.Locking the controller requires using 3 buttons while the controller is in the normal operating (run) mode.

2.Press and hold the Advance/Change/Save button and the Up and Down arrow buttons simultaneously for 20 seconds until the display shows “Locd”.

3.To unlock the controller, press and hold the Advance/Change/Save button and the Up and Down arrow buttons simultaneously for 20 seconds until the display shows “uLoc”.

GENERATOR RUN FEATURE

If desired, the DC3000 controller can be signaled from a standby generator system to lockout (disable operation) of the lag air conditioning system. This is sometimes mandated if the generator size is not sufficient to handle the building load (amperage) and that of all air conditioning systems.

A normally closed (NC) dry contact as part of generator controls is required. These contacts must open when the generator is started, and such action will signal the DC3000 controller to this condition and disable lag air conditioner run function.

On DC3003 with 3 HVAC’s, only the “lag” A/C is locked out; the lead A/C and A/C #3 will still function.

A wire jumper is factory-installedacross the G1 and G2 terminals on main controller board. To utilize the generator run feature, remove the jumper from G1 and G2, and connect the generator normally closed (NC,open-on-run)to the G1 and G2 terminals.

BACKUP DC POWER CONNECTION

There are input connections available for -24VDCor-48VDC(-20to-56V)backup power connection. Making this connection will maintain microprocessor operation, front panel display, LED signaling, and alarm relay operation during periods of commercial power outages and when no standby generator is available. This circuit is protected by a replaceable .5A (500mA) 250V fuse.

IMPORTANT

The shelter DC battery power must be connected to the controller and wired as shown in controller wiring diagrams in order to control the DC Fan ventilation package during periods when AC power is not available.

The backup DC power connection is polarity sensitive. If polarity is reversed, the controller will not function on backup power, no display and no alarm functions will be evident.

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DC FAN CONTROL

The primary reason the DC30002 or DC3003 controller system would be used is for additionally controlling a DC Fan ventilation system installed in the shelter in addition to controlling either 2 or 3 HVAC units. The DC Fan package and intake system is independent of the HVAC systems, and is supplied by others.

A DC Fan pilot-duty control relay, Form C (SPDT) rated at 1A is incorporated into both DC3002 and DC3003 alarm boards for this purpose. DC Fan package must include the load control relay, or be otherwise fieldsupplied.

The DC Fan control can be configured to be used as follows:

1.For emergency ventilation only

2.For both free cooling and emergency ventilation

3.For free cooling only

The controller default setting is “Both”

When economizers are used in HVAC units 1 and 2 and Free Cooling is selected, the economizer controls make the decision when the DC Fan can be active as free cooling or not. The logic is as follows:

1.As long as at least one of the HVAC economizers is operating the DC Fan can operate

2.When outdoor conditions are not acceptable for free cooling using the economizers or when indoor load conditions as such that both economizers are forced off, the DC Fan is turned off. This is monitored by the Unit 1 and Unit 2 “Y” signals feeding from the HVAC 1 and 2 units to the DC3002 or DC3003 internal alarm boards. If both Unit 1 and 2 Y signals are present the DC Fan will not operate in Free Cooling mode.

When economizers are not used, and Free Cooling with the DC Fan is desired, and optional remote sensor Bard Part Number 8612-023must be used.:

1.Sensor is connected to main controller board OUT terminals CU (copper wire) and AG (silver colored wire). The sensor is polarity sensitive and will not work correctly if connected in reverse.

2.The sensor must be located outside the shelter and should be in a junction box for physical protection.

3.It should be on the north side of the shelter if possible to keep from being influenced by the effects of the sun.

4.In the Program menu under “dFon” there are 3 choices for the DC Fan decision for free cooling or not: 50-55-60F.Factory default is 55F.

5.If set-pointis 55F, the outdoor temperature must be 54F or colder for DC Fan to operate. Above 56F the DC Fan would be inhibited for Free Cooling.

For Emergency Ventilation using the DC Fan package, either “Emergency Ventilation Only” or “Both” must be selected in the Program menu. This means that if the shelter temperature rises to 1F above the High Temperature #2set-point,the DC Fan control relay will be energized. The High Temperature #2 alarm relay also is energized at the same time. Default setting for High Temperature #2 is 90F.

NOTE: If economizers are installed, they can also be used for emergency ventilation. See Emergency Ventilation Sequence Using Economizers on page 16.

DC FAN PURGE OPTION

The DC Fan can also be used for intermittent purge cycle if desired for purpose of controlling out-gassingfrom storage batteries or for any other reasons.

DC Fan purge duration is defined in minutes:

1.Shown as “Purg” in Programming Menu

2.Choices are No, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10-minutes

3.Default is set to No

DC Fan purge interval is defined in hours:

1.Shown as “Pint” in Programming Menu

2.Choices are 1, 2, 3, 4, 5, 6, 7, 8 up to 24-hours

3.Default is 1-hour

4.The “Pint” display is suppressed if Purg is set to No

NOTE: The purge interval starts at the end of the selected purge duration.

CONTROLLER WIRING

The DC3002 can be used for controlling two (2) air conditioners with or without economizers. The DC3003 can be used for controlling three (3) air conditioners with or without economizers. Units with economizers will connect differently than units without economizers; therefore, it is important to use the correct connection diagram. See Table 1 for correct connection diagrams.

TABLE 1

 

 

 

Economizer Installed

 

 

 

 

 

 

Connection

Controller

No. of

HVAC

HVAC

HVAC

Diagram

Model

HVAC

#1

#2

#3

 

 

 

 

 

 

Figure 1

DC3002

2

Yes

Yes

---

 

 

 

 

 

 

Figure 2

DC3002

2

No

No

---

 

 

 

 

 

 

Figure 3

DC3003

2 or 3

Yes

Yes

Yes

 

 

 

 

 

 

Figure 4

DC3003

2 or 3

Yes

Yes

No

 

 

 

 

 

 

Figure 5

DC3003

2 or 3

No

No

No

 

 

 

 

 

 

Manual

2100-484E

Page

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