3D Connexion mD4000-b User Manual

INSTALLATION INSTRUCTIONS

& REpLACEMENT pARTS LIST

MD4000 SERIES SOLID STATE

DUAL UNIT LEAD/LAG CONTROLLER

for use with H-Series

Wall Mount Air Conditioners

with F & G Spyder™ Economizers only

Bard Manufacturing Company, Inc.
Bryan, Ohio 43506

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

Manual No.: 2100-574
Supersedes: NEW
File: Vol. III Tab 19
Date: 07-05-12

Manual 2100-574
Page 1 of 23

CONTENTS

Getting Other Information and publications 3
MD4000 General Information

Shipping Damage....................................................4

General ...................................................................4

Theory of Operation ................................................4

 ControllerCertications ...........................................4

Specications/Features for MD4000 Series Controller

MD4000 Controller ..................................................5

Mounting the Controller

Installation Instructions............................................5

Temperature Sensors

Two Optional Sensor Inputs ....................................5

Temperature Sensor Logic

Using Multiple Sensors ...........................................5

Basic MD4000 Controller Input/Output Specs.

MD4000 Controller Connections .............................6

Located in the MD4000 panel Box

Unit #1 & Unit #2 Terminal Block .............................6

Specications/Features for Alarm Boards

MD4000-B & -BC w/Controller Alarms ....................7

Low Voltage Field Wiring

Circuitry in the MD4000...........................................7

Controller Grounding

Earth ground ...........................................................7

Controller power-Up

Time Delay on Power-Up ........................................7

Fire Suppression Circuit

Disabling the MD4000 .............................................8

Staging Delay periods

Stages 1 - 4 .............................................................8

Blower Operation

Various Blower Options ...........................................8

Advance (Swap) Lead/Lag Unit Feature

Manual Switching of Units .......................................8

Accelerate Timer Feature

Testing the Timer Function ......................................8

General programming Overview

Buttons & Function ..................................................9

Heating Sequence of Operation ............................10

Specications Opt. Remote Comm. Board

CB4000 Communications Board ......................11-12

Controller Wiring

Refer to Connection Diagram................................13

Security (Locking) Feature

Locking and Unlocking the MD4000 .....................13

Generator Run / Economizer Shutdown Feature

Standby Generator Disable Operation ..................13

Backup DC power Connection

Input Connections Available ..................................13

Economizer Failure Alarm .....................................16

Dirty Filter Alarm ....................................................16

2-Compressor Run Alarm ......................................16

Alarm Wiring ...........................................................16

2nd Stage Cooling Alarm .......................................17

Refrigerant pressure Alarms .................................17

Spyder Economizer Displays ................................17

Emergency Ventilation Sequence .........................17

programming Instructions .....................................20

Figures

— — — MD4000 Flow Chart ................................10

Figure 1 Controller Connections 1-Stage (H**A/L ....

Series) A/C w/ECONWMT Econ. .............14

Figure 2 Controller Connections 1-Stage (H**A/L ...
Series) A/C w/ ECONWMT Econ. & w/Alarm

Board & CB4000 Comm. Board .............15

— — — Alarm LED Display Board ........................16

Figure 3 Alarm Board Connections for Normally ......

Closed "NC" Open-On-Alarm Strategy ....18

Figure 4 Alarm Board Connections for Normally Open

"NO" Close-On-Alarm Strategy ................................19

— — — MD4000 Label .........................................21

Figure 5 Parts List Description Diagram ................22

Tables

Controller Prog. Features & Defaults ........9

Table 1 Hook-Up Diagram Selection ....................14

Table Parts List .................................................23

Manual 2100-574
Page 2 of 23

Getting Other Information and Publications

These publications can help you install the air

conditioner or heat pump. You can usually nd 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: [phone]
Fax: [phone]

ANSI American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]

ASHRAE American Society of Heating, Refrigerating,
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]

BARD Bard Manufacturing Company, Inc.
1914 Randolph Drive

Bryan, OH 43506
Telephone: [phone]
Fax: [phone]

Manual 2100-574
Page 3 of 23

** 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

The MD4000 is equipped with the B alarm board.
Form C dry contact alarm relays are used, offering

both NO and NC switching to meet the user’s specic
alarm protocol, providing complete exibility to meet

any user's requirements. All alarm actuations are
individually indicated on the controller front panel.

There is an Ethernet based remote communication

option that can be either factory or eld installed. See

section on Communication Module.

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

These instructions explain the operation, installation
and troubleshooting of the MD4000 Series controller.

All internal wiring is complete. Only attach low

voltage eld wiring to designated terminal strips.

The MD4000 is for use with units with economizers.
Each unit should be sized to handle the total load of the

structure if 100% redundancy is required.
The MD4000 controller is suitable for both 50 and 60

HZ operation. See Controller Programmable Features
and Default Settings.

theOrY OF OPeratIOn

The 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 must be used with units with economizers and
both units be equipped alike.

cOntrOller certIFIcatIOns

The MD4000 main controller board, alarm board,
optional communication module, 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:

MD4000 Series

Master Controller

This device complies with FCC Rule Part 15, Subpart
B, Class A. Operation is subject to the following two
conditions:

1. This device may not cause harmful interference

2. This device must accept any interference
received, including that which may cause
undesired operation.

This device complies with CE Standards EN55011/
EN50081 and EN55024 for ISM Equipment, Class A.

This ISM device also complies with Canadian ICES – 001.

Bard Manufacturing Company, Inc.

Bryan, OH 43506

The MD4000 controller is congured for alternative

(lead/lag/lead/lag) sequence, which is default setting.
The MD4000 works in conjunction with the Economizer

Logic Modules to provide room temperature control
based on the DC amp load that the building is using.

The Economizer Logic Modules, in the air conditioner,
control the cooling stages and functions. The MD4000
controls the heating stages, lead lag operation and
alarming operation for the system.

Manual 2100-574
Page 4 of 23

sPecIFIcatIOns/Features FOr
mD4000-b cOntrOller

MD4000 Basic Controller

•Input power: 18-32 VAC, 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 -24 VDC or -48 VDC (-20 to

-56V) maintains microprocessor operation, front panel indication
& alarm relay operation during commercial power outages.

•Digital display: 4-character LCD

•Temperature display: F or C

•HVAC outputs: Form A (NO) relays (1A @ 24 VAC)

•Cooling control stages:

2 for each A/C unit (4 total)

•Heating Control stages:

1 for each A/C unit

•Operating temperature range: 0 to 120F (-18 to 49C)

•Storage temperature range: -20 to 140F (-29 to 60C)

•Temperature accuracy: +/- 1F from 60-85F (16-30C)
+/- 1% outside 60-85F

•Lead/lag changeover time: 0 to 30 days

•Timing accuracy: +/- 1%

•Inter-stage time delay: 10 seconds between stages

•On-Off differential: 2F (1C) is standard, 4F (3C) when

“excessive cycling” mode is enabled

•Comfort setting, Heating 68F(20C), for 1 hour

•Dead band (difference between cooling and heating set

points): 2F to 40F (1.1C to 22.2C)

•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)

•Space temperature sensors: 1 local is standard, will accept up

to 2 optional 25' remote sensors, Bard part number 8612-023.
When multiple sensors are used, temperatures are averaged

•Controller Enclosure: 20-gauge pre-painted steel, 9.25"W
x 20.875"H x 3.00"D, hinged cover, twenty four (24) .875"

diameter electrical knockouts

•LEDs for basic controller: Lead unit, Heating Stages 1 – 4

•Six (6) Push-button controls: On/Off switch-Change lead

unit-Increase & Decrease set points-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 oor-away from drafts &

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 & top of the controller.

If the differential is greater than 12F then the controller
will check to determine the on-board sensor is reading a
temperature that is between the SP (set-point) plus 12F
and the SP minus the DB (dead-band) minus 12F. If it is
the on-board sensor will become the valid sensor reading
and the controller will ignore the local sensor reading. If
it is not then the controller will still use the local sensor
reading. This is to add additional level of operational
capability in the rare event the local sensor fails. If the
controller is operating in this mode it is indicated by the

lower left decimal point ashing in the display. Note: for
purposes of testing when the local sensor is manually
driven higher or lower by applying warm or cool water

to the probe the on-board sensor is inhibited for the rst

30-minutes following power up, or when power is cycled
off and back on.

The controller is designed to accept 1 or 2 additional
sensors and those have 25-foot leads. The Bard part
number for the optional sensor with 25-foot leads is
8612-023. These can be installed as required in the

structure to address hot spots, barriers to airow, etc.

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

The highest reading of any connected 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. Sensor leads can be
extended up to 200 feet. Use 18-gauge twisted pair
with soldered connections.

temPerature sensOr lOGIc

The standard local (LSEn) 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 or more REMOtE sensors are installed and
connected (Rem 1 or Rem 2), the temperature read-out
will display and the building will be controlled to an
average of all 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 multiple temperature sensors are used, the High and
Low temperature alarms will be governed by the average
of the connected sensors.

temPerature sensOrs

The standard (local) temperature sensor has 12" leads and

comes installed from the factory.
A secondary sensor is located internally on the main

controller board and serves as a reference and back-up

sensor to the local sensor. Any differential of +/- 12F

between the on-board and local sensor will cause the
controller to use the local sensor as its point of reference.

Manual 2100-574
Page 5 of 23

basIc mD4000 cOntrOller
InPut/OutPut sPecIFIcatIOns

mD4000 cOntrOller cOnnectIOns

Located on Main Controller Board

Unit #1 C – 24VAC common

R – 24VAC hot
G – fan (Form A, NO)
W – heat (Form A, NO)
Unit #2 C – 24VAC common
R – 24VAC hot
G – fan (Form A, NO)
W – heat (Form A, NO)
F1-F2 Fire/smoke interface
Shipped with jumper installed (a)
48Vdc Back-up power input

-24Vdc or –48Vdc

-20V to –56V range
Local Main sensor, 12-inch leads
CU – copper, AG – silver
Polarity sensitive
Rem 1 Optional remote indoor sensor
CU – copper, AG – silver
Polarity sensitive
Rem 2 Optional remote indoor sensor
CU – copper, AG – silver
Polarity sensitive
H1-H2 Humidity controller input
Requires optional controller
Field installed
Advance Input used to remotely toggle lead/lag change

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

Note: All alarm and output relays are dry contacts rated

1A @ 24 VAC.

Note: All alarm relay outputs have 10-second delay
before issuing to protect against nuisance alarm signals.

NOTE:

Sensors are

solid state,

not RTD.

Use Bard

sensors only.

lOcateD In the mD4000 Panel bOx

Unit #1 terminal Block

R – 24VAC hot from Unit
C – 24VAC common from Unit
Y – Compressor Signal to Unit
F –
A – Compressor Signal from Economizer
4 – Dirty Filter Alarm from Unit
5 – Dirty Filter Alarm from Unit
6 – Signal Common for F
8 – Economizer Fail from Unit
9 – Economizer Fail from Unit
10 – Emergency Vent Output to Economizer
41 – To Unit 2, 43
42 – To Unit 2, 44
43 – To Unit 2, 41
44 – To Unit 2, 42
45 – To Unit 2, 45 DCA Input
46 – To Unit 2, 46 DCA Input
47 – To Unit 1 Display
48 – To Unit 1 Display

Unit #2 terminal Block
R – 24VAC hot from Unit

C – 24VAC common from Unit
Y – Compressor Signal to Unit
F –
A – Compressor Signal from Economizer
4 – Dirty Filter Alarm from Unit
5 – Dirty Filter Alarm from Unit
6 – Signal Common for F
8 – Economizer Fail from Unit
9 – Economizer Fail from Unit
10 – Emergency Vent Output to Economizer

41 – To Unit 1, 43

42 – To Unit 1, 44
43 – To Unit 1, 41
44 – To Unit 1, 42
45 – To Unit 1, 45 DCA Input
46 – To Unit 1, 46 DCA Input
47 – To Unit 2 Display

48 – To Unit 2 Display

Gen Run/Econ Shutdown terminal Block(a)

Economizer Fail terminal Block

Economizer Shutdown Output to Economizer

Economizer Shutdown Output to Economizer

Gen Run Input

Alarm Output

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-site indication of which specic 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.

Manual 2100-574
Page 6 of 23

sPecIFIcatIOns/Features FOr
mD4000-b & -bc cOntrOller alarms

Inputs

Lockout 1 2, 3 – input from HVAC #1
Lockout 2 2, 3 – input from HVAC #2

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
Econ 1 E, F - Form A (NO)
See note (b)
Econ 2 E, F - Form A (NO)
See note (b)
2nd Stage (c) Form C (SPDT)
2

(b) 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.

(c) For units with 2-stage compressors, 2nd stage cooling
alarm activates on cooling Stage 3 initiation.

2nd Compressor Form A (NC)
Dirty Filter Form A (NC)

4, 5 – Input from Unit
Economizer Fail Form A (NC)

8, 9 – Input from Unit

nd

-stage cooling alarm

lOW vOltaGe FIelD WIrInG

The MD4000 is powered from the air conditioners that
it is controlling, 24 VAC (18-32V) low voltage only.

Circuitry in the MD4000 isolates the power supplies of
the two air conditioners so that no back feeds or phasing
problems can occur. Additionally, if one air conditioner
loses power, the MD4000 and the other air conditioner
are unaffected and will continue to operate normally.

Connect the low voltage eld wiring from each unit
per the low voltage eld wiring diagrams in Section on

“Controller Wiring”. NOTE: Maximum of 18-gauge
control wiring should be used. Using heavier gauge
wiring can create excessive stress on the control board
as door is opened and closed. Create a wiring loop so
the door can open and close without stressing terminal
blocks.

cOntrOller GrOunDInG

A reliable earth ground must be connected in addition
to any grounding from conduit. Grounding lugs are
supplied for this purpose.

cOntrOller POWer-uP

Whenever power is rst applied to the controller, there

is a twenty (20) second time-delay prior to any function
(other than display) becoming active. This time-delay
is 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 air
conditioners is removed and then restored.

Manual 2100-574
Page 7 of 23