Bard D28A2PA, D36A2PA, D35A2PA, D28A2PB, D36A2PB Installation And Service Instructions Manual

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INSTALLATION AND

SERVICE INSTRUCTIONS

DUAL-TEC™

WALL-MOUNT PACKAGE

AIR CONDITIONER

Models:

D25A2PA

D28A2PA D28A2PB

D35A2PA D35A2PB

D36A2PA D36A2PB

D42A2PA D42A2PB

D48A2PA D48A2PB

D60A2PA D60A2PB

D25L2PA D25L2PB

D28L2PA D28L2PB

D35L2PA D35L2PB

D36L2PA D36L2PB

Part of the Bard DC Free Cooling Unit System

NOTE: LC Series Controllers must be used with

D-Series Wall-Mount Units

D42L2PA D42L2PB

D48L2PA D48L2PB

D60L2PA D60L2PB

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

www.bardhvac.com

Manual: 2100-643C Supersedes: 2100-643B Date: 7-28-16

Page 1 of 59

CONTENTS

SECTION 1: Installation Instructions ......................................................................................................... 5

List of Necessary Materials/Tools .........................................................................................................................6

Site Preparation .................................................................................................................................................7

Wall-Mount Unit Installation ...............................................................................................................................9

Wall-Mount Unit Supply Wiring ..........................................................................................................................15

Preliminary Start-Up .........................................................................................................................................19

SECTION 2: Service Instructions ............................................................................................................... 21

General Refrigerant Information .........................................................................................................................22

Sequence of Operation .....................................................................................................................................24

Using the TEC-EYE

Componentry Speciﬁcations ..............................................................................................................................30

Maintenance and Troubleshooting ......................................................................................................................38

SECTION 3: Appendix .................................................................................................................................. 45

Wall-Mount Unit Architecture ............................................................................................................................46

FIGURES AND TABLES

Figure 1.1 Wall-Mount Unit Model Nomenclature ......6

Figure 1.2 Dimensions ............................................8

Figure 1.3A D25A, D25L, D35A, D35L

Mounting Instructions ...........................10

Figure 1.3B D28A, D28L, D36A, D36L, D42A, D42L,

Mounting Instructions ...........................11

Figure 1.3C D48A, D48L, D60A, D60L

Mounting Instructions ...........................12

Figure 1.4 Electric Heat Clearance .........................13

Figure 1.5 Wall Mounting Instructions ....................13

Figure 1.6 Wall Mounting Instructions ....................14

Figure 1.7 Common Wall Mounting Installations ......14

Figure 1.8 Circuit Routing Label ............................15

Figure 1.9 WIRING: VAC and VDC Supply Wiring

Landing Points .....................................17

Figure 1.10 Adjusting the 230/208VAC Transformer ..17

Figure 1.11 Bard Polarity-Voltage Monitor .................18

Figure 2.1 Refrigerant Sight Glass .........................23

Figure 2.2 Wall-Mount Unit Control Board ..............25

Figure 2.3 TEC-EYE Figure 2.4 TEC-EYE Figure 2.5 TEC-EYE

Figure 2.6 Fan Blade Setting .................................32

Figure 2.7 Dirty Filter Switch .................................32

Figure 2.8 Power Loss Relay Circuit .......................33

Figure 2.9 High Pressure Relay Circuit ...................33

Figure 2.10 Blower Motor Start Relay Circuit ............33

Figure 2.11 D25A/L, D35A/L Unit Control Panel .......34

Figure 2.12 D28A/L, D36A/L, D42A/L, D48A/L,

D60A/L Unit Control Panel ....................35

Figure 2.13 WIRING: D25A/L, D35A/L

Unit Wiring Diagram .............................36

Figure 2.14 WIRING: D28A/L, D36A/L, D42A/L, ..........

D48A/L, D60A/L Unit Wiring Diagram ....37

Figure 2.15 Troubleshooting Motor Power Supply ......39

Figure 2.16 Troubleshooting Motor Start Command ...40

Figure 2.17 Troubleshooting Speed Voltage ...............40

Figure 2.18 VDC Polarity Check ...............................41

Figure 2.19 Verifying Incoming Voltage: VDC .............42

........................................................................................................................................27

Table 1.1 Electrical Speciﬁcations ..........................16

Table 2.1 Nominal Pressures ..................................23

Table 2.2 Blower Speed Voltage Chart .....................24

Table 2.3 Temp vs. Resistance of Temp Sensor. ........31

Table 2.4 Indoor Blower Performance ......................32

Table 2.5 Troubleshooting 48VDC Blower Motor ........39

Table 2.6 Blower Speed Voltage Chart .....................40

Display ................................27

Connection to Unit Control ....27

Status Display......................28

Manual 2100-643C Page 2 of 59

GENERAL INFORMATION

DC FREE COOLING UNIT SYSTEM

The Bard DC Free Cooling Unit system is composed of two (2) D-Series DUAL-TEC™ wall-mount air conditioners matched with one (1) LC Series lead/lag controller. The D-Series, speciﬁcally engineered for the telecom market, can provide outdoor air cooling during power loss situations through the use of onsite -48VDC positive ground battery banks.

NOTE: The LC Series lead/lag controller and the

D-Series wall-mount units are designed speciﬁcally to work together. The controller cannot run other Bard models or other brands of systems, nor can other controllers or thermostats run the D-Series wall-mount units. They are a complete system, and must be used together.

WALL-MOUNT AIR CONDITIONER UNITS

The D-Series units operate on both VAC and VDC power under normal power supply conditions. If there is loss 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 relief openings in the shelter.

Each of these units are fully charged with refrigerant and have auxilliary heat installed.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The refrigerant system is completely assembled and charged. All internal wiring is complete.

The unit is designed for use 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 system should be carefully read before beginning the installation. Note particularly any tags and/or labels attached to the equipment.

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See ADDITIONAL PUBLICATIONS for information on codes and standards.

Sizing of systems for proposed installation should be based on heat loss calculation made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the Standards of the National Fire Protection

Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where

local regulations are at a variance with instructions, installer should adhere to local codes.

SHIPPING DAMAGE

Upon receipt of equipment, the cartons should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

These units must remain in upright position at all times.

ADDITIONAL PUBLICATIONS

These publications can help when installing the air conditioning system. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current edition of each standard.

National Electrical Code ...................... ANSI/NFPA 70

Standard for the Installation of Air Conditioning

and Ventilating Systems ...................ANSI/NFPA 90A

Standard for Warm Air Heating

and Air Conditioning Systems ............ANSI/NFPA 90B

Load Calculation for Residential Winter

and Summer Air Conditioning ............. ACCA Manual J

Duct Design for Residential Winter and Summer Air Conditioning and Equipment Selection

....................................................... ACCA Manual D

For more information, contact these publishers:

Air Conditioning Contractors of America (ACCA) 1712 New Hampshire Ave. N.W. Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721

American National Standards Institute (ANSI)

11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286

Manual 2100-643C Page 3 of 59

American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE)

1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478

National Fire Protection Association (NFPA)

Batterymarch Park P. O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057

ANSI Z535.5 Deﬁnitions:

Danger: Indicate[s] a hazardous situation which, if

not avoided, will result in death or serious injury. The signal word “DANGER” is to be limited to the most extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved.

Warning: Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. WARNING [signs] should not be used for property damage hazards unless personal injury risk appropriate to this level is also involved.

Caution: Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION [signs] without a safety alert symbol may be used to alert against unsafe practices that can result in property damage only.

Notice: [this header is] preferred to address practices not related to personal injury. The safety alert symbol shall not be used with this signal word. As an alternative to “NOTICE” the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.

WARNING

Electrical shock hazard.

Have a properly trained individual perform these tasks.

Failure to do so could result in electric shock or death.

WARNING

Fire hazard.

Maintain minimum 1/4” clearance between the supply air duct and combustible materials in

the rst 3’ feet of ducting.

Failure to do so could result in re causing damage, injury or death.

WARNING

Heavy item hazard.

Use more than one person to handle unit.

Failure to do so could result in unit damage or serious injury.

Manual 2100-643C Page 4 of 59

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp edges.

Failure to do so could result in personal injury.

SECTION 1:

INSTALLATION

INSTRUCTIONS

Manual 2100-643C Page 5 of 59

LIST OF NECESSARY MATERIALS/TOOLS

Additional hardware and miscellaneous supplies are needed for installation. These items are ﬁeld supplied and must be sourced before installation. This list also includes tools needed for installation.

LIST OF MATERIALS/TOOLS

• Personal protective equipment/safety devices

• Supply/return grilles

• Field-fabricated sleeves (if necessary)

• Fasteners sufﬁcient for mounting the units such as 5/16" diameter anchor/carriage/lag bolts

• 7/8" diameter washers

• Caulking materials

• Miscellaneous hand and power tools and jobsite or shop materials

• Lifting equipment with the necessary capacity and rigging to safely move/install the systems

• Electrical supplies:

- Two (2) 20A circuit breakers for the shelter DC

power plant (one per wall-mount unit)

- Two (2) various size circuit breakers for

the shelter AC breaker box (see Table 1.1: Electrical Speciﬁcations on page 16)

- High-voltage wire of various gauges (see Table

1.1)

- Communication wire: 2-wire, 18 gauge,

shielded with drain

- Miscellaneous electrical supplies including

rigid/flexible conduit and fittings, junction boxes, wire connectors and supports

The following are required and must be sourced prior to installation of these units.

• Two (2) 20A circuit breakers for the shelter DC power plant (one per wall-mount unit)

Circuit breakers for Emerson Network Power (ENP) power plants (used in most telecomm shelters built today) are available directly through the following distributors:

• Emerson Network Power: 440.288.1122

• Master Electronics: 888.473.5297 or

www.onlinecomponents.com

Emerson Network Power (ENP) Part Number

• 20A circuit breaker: P/N 101601

Always conﬁrm the application before ordering.

FIGURE 1.1

D-Series DUAL-TEC™ Wall-Mount Unit Model Nomenclature

D 25 A 2 P A 05 4 P X X X J

MODEL

SERIES

CAPACITY

25 – 2 Ton

28 – 2½ Ton

35 – 3 Ton 36 – 3 Ton

Manual 2100-643C Page 6 of 59

42 – 3½ Ton 48 – 4 Ton 60 – 5 Ton

A – Right Hand

L – Left Hand

REVISION

PLC

VOLTS & PHASE

A – 230/208-60-1 B – 230/208-60-3

0Z – 0 KW 05 – 5 KW 06 – 6 KW

-48VDC

Free Cooling

Unit

COIL OPTIONS

X – Standard 3 – Phenolic Coated Evaporator and Condenser

SPECIAL FEATURES

COLOR OPTIONS

X – Beige 1 – White 4 – Buckeye Gray

FILTER OPTIONS

P – 2-Inch Pleated (MERV 8) M – 2-Inch Pleated (MERV 11)

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

SITE PREPARATION

NEW SHELTER INSTALLATION VS. RETROFIT INSTALLATION

These installation instructions cover both new shelter installations and retroﬁt installations. Each installation is unique and may require special accomodations and modiﬁcations. Although Bard Manufacturing follows a long-established tradition of manufacturing equipment using industry standard dimensions for building penetration, it is occasionally necessary to move or enlarge supply and return openings when replacing non-standardized equipment in a retroﬁt application.

MINIMUM CLEARANCE

D-Series wall-mount air conditioners are available in both right-hand access models and left-hand access models. Right-hand access models have the heat strip access panel, external circuit breakers access panel and internal controls access panel on the right side of the unit. Left-hand access models are a mirror image of the right-hand access models, and allow two wallmount units to be placed in relatively close proximity and yet still allow complete access for maintenance and repair.

On side-by-side installations, maintain a minimum of 26" clearance on control side to allow access to control panel and heat strips, and to allow proper airﬂow to the outdoor coil. For installations where units are installed with both control panels facing each other (inward), maintain a minimum of 36" clearance to allow access. Additional clearance may be required to meet local or national codes.

Care should be taken to ensure that the recirculation and obstruction of condenser discharge air does not occur. Recirculation 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 as the D-Series units, it is recommended there be a minimum distance of 10' between the front of the unit and any barrier or 20' between the fronts of two opposing (facing) units.

CLEARANCE TO COMBUSTIBLES

WARNING

Fire hazard.

Maintain minimum 1/4" clearance between the supply air duct and combustible materials in

the rst 3' of ducting.

Failure to do so could result in re causing damage, injury or death.

The unit itself is suitable for 0" clearance, but the supply air duct ﬂange and the ﬁrst 3' of supply air duct require a minimum of 1/4" clearance to combustible material. However, it is generally recommended that a 1" clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figures 1.3A-C on pages 10-12 for details on opening sizes.

Minimum Clearances Required to Combustible Materials

MODELS

All covered by this manual

SUPPLY AIR DUCT

FIRST 3'

1/4" 0"

CABINET

MODEL IDENTIFICATION

Identify the speciﬁc model using the model nomenclature information found in Figure 1.1 and/ or model/serial tag found on the unit on the opposite side of the control and access panels. See Figure 1.2 on page 8 for dimensions and critical installation requirements.

Clearances Required for Service Access and Adequate Condenser Airﬂow

MODELS LEFT SIDE RIGHT SIDE

All covered by this manual 26" 26"

Units with control panels facing each other (inward)

36" between units

Manual 2100-643C Page 7 of 59

FIGURE 1.2

Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)

Width

Depth

Model

D25A/L D35A/L

D28A/L D36A/L D42A/L

D48A/L D60A/L

(W)

38.200 17.125 74.563 7.88 27.88 13.88 27.88 40.00 10.88 29.75 17.93 30.75 32.75 33.25 31.00 2.75 39.13 26.75 9.14 4.19 12.00 9.00

42.075 22.432 84.875 9.88 29.88 15.88 29.88 43.88 13.56 31.66 30.00 32.68 26.94 34.69 32.43 3.37 43.00 23.88 10.00 1.44 16.00 1.88

42.075 22.432 93.000 9.88 29.88 15.88 29.88 43.88 13.56 37.00 30.00 40.81 35.06 42.81 40.56 3.37 43.00 31.00 10.00 1.44 16.00 10.00

Height

(D)

Supply Return

(H)

A B C B E F G I J K L M N O P Q R S T

All dimensions are in inches. Dimensional drawings are not to scale.

Side View

Built In Rain Hood 4° Pitch

1.250

Cond.

Air

Inlet

1.250

2.13

Drain

Electric Heat

C H

Heater Access Panel

C. Breaker/ Disconnect Access Panel (Lockable)

Econ. Hood

Side Wall Mounting

Brackets

(Built In)

Top Rain

Flashing Shipping Location

Optional

Electrical

Entrances

E O

Supply Air Opening

Return Air Opening

Back View

D**A

RIGHT

HAND

UNIT

D**L LEFT

HAND

UNIT

Built In

Rain Hood

ECON Hood

Ventilation Air

Cond.

Air

Outlet

4° Pitch

Heater

Access

Panel

Electric

Heat

C. Breaker/ Disconnect

Access Panel

(Lockable)

7.000

Low Voltage

Electrical

Entrance

High Voltage

Electrical

Entrance

Front View

.44

Supply Air Opening

Side Wall Mounting Brackets (Built In)

Top Rain

Flashing Shipping Location

2.13

.44

Bottom Installation Bracket

MIS-3849

Drain

Return Air Opening

Bottom

Installation

Bracket

Back View

Manual 2100-643C Page 8 of 59

Optional Electrical Entrances

Ventilation Air

Cond.

Air

Inlet

7.000

Low Voltage Electrical Entrance

High Voltage Electrical Entrance

Condenser

Air Outlet

Front ViewSide View

MIS-3848

WALL-MOUNT UNIT INSTALLATION

MOUNTING THE UNITS

WARNING

Heavy item hazard.

Use more than one person to handle unit.

Failure to do so could result in unit damage or serious injury.

NOTE: It may be best to spot some electrical knockouts (such as those located on the back of the wallmount unit) before units are mounted and access is unavailable or limited (see Figure 1.2 to locate prepunched knockouts).

Two holes for the supply and return air openings must be cut through the wall as shown in Figures 1.3AC on pages 10-12. On wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit.

In retroﬁt (unit replacement) installations, the openings cut for the original equipment may not line up exactly with needs of this installation. Modiﬁcations may need to be made, such as increasing or decreasing the size of the wall cutouts. The existing bolt placement may not line up in which case the original bolts would need to be removed or cut away.

1. These units are secured by wall mounting ﬂanges which secure the unit to the outside wall surface at both sides. A bottom mounting bracket, attached to skid for shipping, is provided for ease of installation, but is not required.

2. The unit itself is suitable for 0" clearance, but the supply air duct ﬂange and the ﬁrst 3' of supply air duct require a minimum of 1/4" clearance to combustible material. However, it is generally recommended that a 1" clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figures

1.3A-C for details on opening sizes.

3. Locate and mark lag bolt locations and location for optional bottom mounting bracket, if desired (see Figures 1.3A-C).

4. Mount bottom mounting bracket (if used).

5. If desired, hook top rain ﬂashing (attached to frontright of supply ﬂange for shipping) under back bend of top.

6. Position unit in opening and secure with fasteners sufﬁcient for the application such as 5/16" lag/ anchor/carriage bolts; use 7/8" diameter ﬂat washers on the bolts. It is recommended that a bead of silicone caulking be placed behind the side mounting ﬂanges.

7. Secure optional rain ﬂashing to wall and caulk across entire length of top (see Figures 1.3A-C).

8. For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall.

9. A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.

Manual 2100-643C Page 9 of 59

FOUR SIDES OF SUPPLY

Wall Opening and Hole Location View

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALSCRECOMMENDED 1" CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

AIR DUCT IS REQUIRED

1/4" CLEARANCE ON ALL

FROM COMBUSTABLE

MIS-3820

MATERIALS

FOAM AIR SEAL

SUPPLIED

RAIN FLASHING

SEAL WITH BEAD

FIGURE 1.3A

OF CAULKING ALONG

Mounting Instructions

ENTIRE LENGTH OF TOP.

D25A, D25L, D35A, D35L

17 5/8

3 11/16

TOP

4 7/16

WALL STRUCTURE

WALL

SUPPLY AIR

DUCT

PANEL

HEATER ACCESS

TOP FLASHING AT TIME OF INSTALLATION.

IT IS RECOMMENDED THAT A BEAD OF

THE SIDE MOUNTING FLANGES AND UNDER

RETURN AIR

OPENING

NOTES:

SILICONE CAULKING BE PLACED BEHIND

W**A UNIT SHOWN, W**L UNIT

CONTROLS AND HEATER ACCESS

IS ON OPPOSITE (LEFT) SIDE.

Right Side View

14"

5 3/8

8 3/8A9 7/829 7/8

4 5/8 16 7/8

28 3/8

Manual 2100-643C Page 10 of 59

Supply Opening

Return Opening

28"

12"

Typ.

12"

Typ.

16"

" 6

Typ.

30"

16"

A CC

Wall Opening and Hole Location View

RETURN AIR

REQUIRED DIMENSIONS TO MAINTAIN

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

DUCT

COMBUSTIBLE MATERIALS

A B C DE

30 1/2

10 1/2

6 1/4 1 1/4 29 3/4

32 12 5 1/2

NOTES:

WALL STRUCTURE

SUPPLY AIR

IT IS RECOMMENDED THAT A BEAD OF

OPENING

Right Side View

RAIN FLASHING

SILICONE CAULKING BE PLACED BEHIND

RECOMMENDED 1" CLEARANCE FROM

THE SIDE MOUNTING FLANGES AND UNDER

TOP FLASHING AT TIME OF INSTALLATION.

TOP.

PANEL

HEATER ACCESS

FOUR SIDES OF SUPPLY

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

WALL

1/4" CLEARANCE ON ALL

MATERIALS

Supply Opening

FOAM AIR SEAL

SUPPLIED

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF

TOP

Return Opening

MIS-416 E

Dimension is 21" on 95" tall units.

Dimension is 10" on T48H1 & T60H1.

Dimension is 6" on T48H1 & T60H1.

FIGURE 1.3B

Mounting Instructions

D28A, D28L, D36A, D36L, D42A, D42L

Manual 2100-643C Page 11 of 59

16"

" 5

8 97

Typ.

30"

16"

A CC

1 1/430 1/2

1/4" CLEARANCE ON ALL

SUPPLIED

FOAM AIR SEAL

Supply Opening

SILICONE CAULKING BE PLACED BEHIND

DUCT

FOUR SIDES OF SUPPLY

FROM COMBUSTABLE

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

OPENING

COMBUSTIBLE MATERIALS

B D E

PANEL

AIR DUCT IS REQUIRED

10 1/2

Right Side View

SUPPLY AIR

RECOMMENDED 1" CLEARANCE FROM

MIS-3789

RAIN FLASHING

REQUIRED DIMENSIONS TO MAINTAIN

TOP.

MATERIALS

5 1/2

WALL STRUCTURE

6 1/4

29 3/4

IT IS RECOMMENDED THAT A BEAD OF

THE SIDE MOUNTING FLANGES AND UNDER

WALL

Wall Opening and Hole Location View

NOTES:

TOP FLASHING AT TIME OF INSTALLATION.

HEATER ACCESS

RETURN AIR

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF

TOP

Return Opening

FIGURE 1.3C

Mounting Instructions

D48A, D48L, D60A, D60L

Manual 2100-643C Page 12 of 59

FIGURE 1.4

DUCT

OPENING

RETURN AIR

SUPPLY AIR

WOOD FRAME 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

Electric Heat Clearance

Wall Mounting Instructions

See FIGURE 2 – Mounting Instructions

FIGURE 1.5

Manual 2100-643C Page 13 of 59

FIGURE 1.6

E + 1.000

1.000

SUPPLY DUCT

OVER FRAME

INTERIOR FINISHED WALL

ALL AROUND DUCT

FRAMING MATERIAL

EXTERIOR FINISH WALL

OPENING

FOR ACTUAL DIMENSIONS.

2 x 4'S, 2 x 6'S &/OR

STRUCTURAL STEEL

ATTACH TO TOP

1.000" CLEARANCE

PLATE OF WALL

SEE UNIT DIMENSIONS, FIGURE 2,

OPENING

RETURN DUCT

2 x 6

ATTACH TO BOTTOM

OVER FRAME

PLATE OF WALL

THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS.

MIS-549 B

ALL AROUND DUCT

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC

OPENING W/ GRILLE

SUPPLY AIR DUCT

RAFTERS

RETURN AIR OPENING W/ GRILLE

DUCTED SUPPLY

OR BELOW CEILING RAFTERS AS SHOWN

FINISHED CEILING SURFACE

RAIN

FLASHING

RAIN

FLASHING

RETURN AT UNITNO DUCT

RETURN AIR

FINISHED CEILING SURFACE

FREE AIR FLOW

OUTSIDE

WALL

OUTSIDE

WALL

SUPPLY AIR DUCT W/ GRILLE

Wall Mounting Instructions

SEE UNIT DIMENSIONS, FIGURE 1-2, FOR ACTUAL DIMENSIONS

FIGURE 1.7

Common Wall Mounting Installations

Manual 2100-643C Page 14 of 59

WALL-MOUNT UNIT SUPPLY WIRING

NOTICE / AVIS

ROUTE ALL HIGH VOLTAGE FIELD

WIRES TO THE RIGHT OF THE WIRE

SHIELD AS SHOWN

ACHEMINER LES FILS HAUTE

TENSION SUR LA DROITE VERS LA

PROTECTION, COMME INDIQUÉ

VAC CIRCUIT BREAKER

/DISJONCTEUR

WIRE SHIELD /

PROTECTION

WHITE 3/16" LETTERING

7961-807

VDC CIRCUIT BREAKER

/DISJONCTEUR

All models covered by this installation instruction require dual power sources: VAC utility power to run the compressor, heat and outdoor fan motor and -48 VDC power to operate the indoor blower and DC free cooling damper.

These units require a positive ground

-48 VDC copper conductor ﬁeld wire connection. Refer to the unit wiring diagram

for more information.

WARNING

Route all ﬁeld wires to the right of the wire shield as shown in the circuit routing label found in Figure 1.8 (and also on the wall-mount units).

Run communication wires in separate conduit whenever possible. If a unique installation occurs where it is not possible to isolate the communication wires, it is permissible to run communication wires in a conduit which contains a dedicated VDC voltage line. In all cases, the communication wires must be shielded, twisted wire and utilize proper ﬁltration at the main communications board. It is never permissible to

run communication wires with VAC voltage lines.

FIGURE 1.8

Circuit Routing Label

Electrical shock hazard.

Have a properly trained individual perform these tasks.

Failure to do so could result in electric shock or death.

Refer to the unit rating plate or Table 1.1 on page 16 for wire sizing information and maximum fuse or circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. The ﬁeld wiring used must be sized to carry models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75°C copper) for all models including the most commonly used heater sizes. Also shown are the number of ﬁeld power circuits required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

that amount of current. All

See Figure 1.9 on page 17 to reference VAC and VDC supply wiring landing points.

IMPORTANT: 230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. It is very important that the correct voltage tap is used. For 208V operation, reconnect from 240V to 208V tap (see Figure 1.10). The acceptable operating voltage range for the 240 and 208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197).

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left-hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry.

Manual 2100-643C Page 15 of 59

TABLE 1.1

Electrical Speciﬁcations

AC POWER CIRCUIT DC POSITIVE GROUND POWER CIRCUIT

Model

D25A2PA0Z/D25L2PA0Z 208/230-60-1 19 30 10/10 15.6 20 12

D25A2PA05/D25L2PA05 208/230-60-1 26 30 8/10 15.6 20 12

D35A2PA0Z/D35L2PA0Z 208/230-60-1 24 40 8/10 15.6 20 12

D35A2PA05/D35L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D35A2PB0Z/D35L2PB0Z 208/230-60-3 19 25 10/10 15.6 20 12

D35A2PB06/D35L2PB06 208/230-60-3 19 25 10/10 15.6 20 12

D28A2PA05/D28L2PA05 208/230-60-1 26 30 10/10 15.6 20 12

D28A2PB06/D28L2PB06 208/230-60-3 18 20 12/12 15.6 20 12

D36A2PA05/D36L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D36A2PB06/D36L2PB06 208/230-60-3 18 25 10/10 15.6 20 12

D42A2PA05/D42L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D42A2PB06/D42L2PB06 208/230-60-3 20 25 10/10 15.6 20 12

D48A2PA05/D48L2PA05 208/230-60-1 30 50 8/10 15.6 20 12

D48A2PB06/D48L2PB06 208/230-60-3 20 30 10/10 15.6 20 12

D60A2PA05/D60L2PA05 208/230-60-1 36 60 6/10 15.6 20 12

D60A2PB06/D60L2PB06 208/230-60-3 30 40 8/10 15.6 20 12

Rated Volts,

Hertz & Phase

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

These “Minimum Circuit Ampacity” values are to be used for sizing the ﬁeld power conductors. Refer to the National Electric Code (latest version), Article 310 for power conductor sizing.

CAUTION: When more than one ﬁeld power circuit is run through one conduit, the conductors must be derated. Pay special attention

to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three current carrying conductors are in a raceway.

Maximum size of the time delay fuse or circuit breaker for protection of ﬁeld wiring conductors. Based on 75°C copper wire. All wiring must conform to the National Electric Code and all local codes.

Manual 2100-643C Page 16 of 59

FIGURE 1.9

VAC and VDC Supply Wiring Landing Points

Field Wiring

VDC

Factory

Wiring

VAC

Field Wiring

Factory

NOTE: Right-hand access model wiring landing points

are shown here; left-hand access models will mirror this image.

Wiring

NOTE: Right-hand access model wiring landing points

are shown here; left-hand access models will mirror this image.

FIGURE 1.10

Adjusting the 230/208 VAC Transformer

230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. It is very important that the correct voltage tap is used. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197).

1. Verify incoming AC voltage: Multimeter set to VAC

2. If incoming AC voltage is 220VAC or above...

...do not adjust transformer

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

3. If incoming AC voltage is below 220VAC...

...shut off AC breaker to unit

and move factory "240V" wire to "208V" terminal

Manual 2100-643C Page 17 of 59

FIGURE 1.11

Bard Polarity-Voltage Monitor

If the VDC wiring is not terminated correctly on the speciﬁc polarity-indicated terminals of the VDC terminal block, the VDC controls and motors will not activate and the wall-mounted unit will not function.

The Bard Polarity-Voltage Monitor continually monitors for correct polarity and voltage. If ﬁeld wiring is connected improperly, or the voltage is outside of the system parameters, the Polarity-Voltage Monitor will not allow any VDC voltage to enter the system, protecting the internal controls and equipment.

When ﬁeld wiring is correct in voltage and polarity, the green power (PWR) LED and yellow polarity (POL) LED will light, and system will operate normally.

If ﬁeld wiring is incorrect in polarity, the red FAULT LED will light, and the monitor will not allow VDC voltage into the system.

If ﬁeld wiring is correct in polarity but outside of the required 40VDC – 56VDC, the green PWR LED will not illuminate and the monitor not allow VDC voltage into the system.

If the Polarity-Voltage Monitor is showing a problem with polarity and/or voltage, see pages 41 and 42 of the Service section of this manual for instructions on checking VDC polarity and verifying incoming VDC voltage.

Manual 2100-643C Page 18 of 59

PRELIMINARY START-UP

RUNNING IN STAND ALONE (ORPHAN) MODE

With both AC and DC breakers turned on, each D-Series wall-mount system has the capability to run without the controller attached—this feature is called Stand Alone or Orphan Mode, and it basically keeps the shelter between 60°F and 78°F by the use of the factory-installed return air sensor in each wall-mount unit.

During installation, this allows deactivation 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-mount unit and controller are installed.

Additionally, should either or both D-Series wall-mount units lose communication with the controller (such as during maintenance), they will continue to serve the shelter's needs until a repair can be made.

See the LC Series controller manual for information on connecting the communication wiring from the controller to the two wall-mount units and operating the DC free cooling unit system.

Manual 2100-643C Page 19 of 59

Manual 2100-643C Page 20 of 59

SECTION 2:

SERVICE

INSTRUCTIONS

Manual 2100-643C Page 21 of 59

GENERAL REFRIGERANT INFORMATION

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

These units require R-410A refrigerant and polyol ester oil.

GENERAL

1. Use separate service equipment to avoid cross contamination of oil and refrigerants.

2. Use recovery equipment rated for R-410A refrigerant.

3. Use manifold gauges rated for R-410A (800 psi/250 psi low).

R-410A is a binary blend of HFC-32 and HFC-125.

5. R-410A is nearly azeotropic—similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.

6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.

7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.

8. R-410A compressors use polyol ester oil.

9. Polyol ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.

10. A liquid line dryer must be used—even a deep vacuum will not separate moisture from the oil.

11. Limit atmospheric exposure to 15 minutes.

12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.

TOPPING OFF SYSTEM CHARGE

If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above) and charging to the nameplate charge. If done correctly, topping off the system charge can be done without problems.

With R-410A, there are no signiﬁcant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge in the system may be used after leaks have occurred. “Top-off” the charge by utilizing the pressure charts on the inner control panel cover as a guideline.

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 irritating to the skin, and liquid refrigerant will freeze the skin.

3. Never use air and R-410A to leak check; the mixture may become ﬂammable.

4. Do not inhale R-410A—the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimately death can result from breathing this concentration.

5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed.

6. Use only cylinders rated DOT4BA/4BW 400.

7. Never ﬁll cylinders over 80% of total capacity.

8. Store cylinders in a cool area, out of direct sunlight.

9. Never heat cylinders above 125°F.

10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands signiﬁcantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.

R410-A REFRIGERANT CHARGE

This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efﬁciency ratings were determined by testing with this refrigerant charge quantity.

The pressure table found on the following page shows nominal pressures for the units. Since many installation speciﬁc situations can affect the pressure readings, this information should only be used by certiﬁed technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge.

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. A pressure table covering all models can be found on page 23. It is imperative to match the correct pressure table to the unit by model number.

Manual 2100-643C Page 22 of 59

This unit employs high-ﬂow Coremax valves instead of the typical Shrader type valves.

WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result in eye injuries or refrigerant burns!

TABLE 2.1

Nominal Pressures

To change a Coremax valve without ﬁrst removing the refrigerant, a special tool is required which can be obtained at www.fastestinc.com/en/SCCA07H. See the replacement parts manual for replacement core part numbers.

Model

D25A/L

D28A/L

D35A/L

D36A/L

D42A/L

D48A/L

D60A/L

Return Air

Temperature

75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB 75° DB

62° WB 80° DB

67° WB 85° DB

72° WB

Pressure

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side Pressure ±4 PSIG High Side Pressure ±10PSIG

Air Temperature Entering Outdoor Coil, Degree °F

75 80 85 90 95 100 105 110 115 120

132

133

134

136

137

138

140

142

144

292 141

299 146

309 137

279 146

286 151

296 118

327 126

335 130

347 133

313 142

321 147

332 131

315 140

323 145

334 133

325 142

333 147

345 129

353 138

362 143

375

308 142

316 147

327 137

299 146

307 151

318 120

349 128

358 132

371 135

327 144

335 149

347 132

331 141

339 146

351 136

341 145

350 150

362 130

362 139

371 144

384

327 143

335 148

347 137

321 147

329 152

341 122

371 131

381 136

394 137

342 146

351 151

363 134

348 143

357 148

369 137

360 147

369 152

382 132

374 141

384 146

397

347 145

356 150

368 139

342 149

351 154

363 125

396 134

406 139

420 138

361 148

370 153

383 136

368 145

377 150

390 139

379 149

389 154

403 133

390 142

400 147

414

369 146

378 151

391 140

366 150

375 155

388 127

421 136

432 141

447 139

382 149

392 154

406 137

388 147

398 152

412 141

401 151

411 156

425 134

410 143

420 148

435

392 148

402 153

416 141

389 151

399 156

413 129

448 138

459 143

475 141

406 151

416 156

431 139

410 149

421 154

436 142

424 152

435 157

450 136

432 145

443 150

459

417 150

428 155

443 143

413 153

424 158

439 132

475 141

487 146

504 143

432 153

443 158

459 142

435 152

446 157

462 144

449 154

461 159

477 137

458 146

470 151

486

445 152

456 157

472 144

439 154

450 159

466 134

504 143

517 148

535 145

461 155

473 160

490 144

461 154

473 159

490 145

477 155

489 160

506 137

488 147

501 152

519

474 154

486 159

503 146

464 156

476 161

493 136

533 145

547 150

566 147

492 157

505 162

523 146

489 156

502 161

520 147

505 157

518 162

536 139

522 149

535 154

554

147 505

157 518

162 536

148 491

158 504

164 522

137 565

147 579

152 599

149 527

159 540

165 559

149 520

159 533

165 552

148 535

158 549

164 568

140 559

150 573

155 593

FIGURE 2.1

Refrigerant Sight Glass

Capacitors

Part No. Ratings

8552-050

8552-002

8552-055

8552-005

8552-052

8552-002

8552-079

8552-005

8552-079

8552-005

8552-089

8552-005

8552-058

8552-005

1 Ø, 240V

40+15/370

3 Ø, 240V

5/370

1 Ø, 240V

40+.10/370

3 Ø, 240V

10/370

1 Ø, 240V

45+15/370

3 Ø, 240V

5/370

1 Ø, 240V

45+10/370

3 Ø, 240V

10/370

1 Ø, 240V

45+10/370

3 Ø, 240V

10/370

1 Ø, 240V

70+10/370

3 Ø, 240V

10/370

1 Ø, 240V

80+10/440

3 Ø, 240V

10/370

The refrigerant sight glass installed in this unit is not a charging indicator. The sight glass is for moisture reference only. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge.

Manual 2100-643C Page 23 of 59

SEQUENCE OF OPERATION

D-SERIES WALL-MOUNT UNIT SEQUENCE OF OPERATION

Overview

This product is designed to function like a typical telecom air conditioning system with an outdoor aircooling damper. However, the DC Free Cooling Unit system does have some special features, like a control board which allows for advanced alarming and a “DC Free Cooling” feature that allows for forced emergency ventilated cooling anytime “shore power” VAC power from the utility company is lost. The internal controls within this unit automatically recognize a loss of shore power, energizing the indoor blower motor and powering the actuator to open the damper to bring in outdoor air. The power utilized during this time is the stored battery power from the equipment shelter.

Indoor Blower

The indoor blower is a 48VDC motor, completely separate from the VAC circuit(s). For the blower to activate, two separate actions must take place:

1. 24VDC from terminal N07 (Blower Motor Start Relay)

2. 0-10VDC signal from terminal Y1 (Speed Voltage)

While the 24VDC from N07 will always stay the same, the 0-10VDC signal from terminal Y1 will vary depending upon the mode. See Table 2.2.

DC Free Cooling Damper

This controller is enabled for dewpoint control, speciﬁcally examining the combination of temperature and relative humidity to determine the proper control of cooling. The system will utilize free cooling when the following conditions are true:

1. The outdoor temperature is below 70°F

2. The dewpoint of the outdoor air is below 60°F

3. The outdoor humidity is below 80% RH

4. The indoor humidity is below 60% RH

To signal the 24VDC damper actuator to open, a 2-10VDC signal must come from the Y2 terminal. Additionally, while other modes get only a single speed from the indoor blower, free cooling mode will get two: 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 outdoor humidity and the indoor temperature.

• If the outdoor temperature and humidity ratio are conducive to free cooling, the control board will send:

1. 2-10VDC Signal from Y2 (Damper Signal)

- Modulates damper to achieve 55°F at

supply air temperature sensor

2. 24VDC from terminal N07 (Blower Motor Start

Relay)

3. 0-10VDC signal from terminal Y1 (Speed

Voltage)

• If the outdoor conditions are conducive to free cooling, but a 2nd stage cooling call is generated, the board will additionally add 24VAC signal from the N02 terminal to the CCM, activating the compressor. The damper will limit outdoor air to keep supply air temperature at 55°F.

Model Blower Only

D25A/D25L

D28A/D28L 800/2.8 1100/3.8 1800/7.0

D35A/D35L 1100/3.0 1100/4.0 1100/4.0

D36A/D36L 800/2.8 1100/3.8 1800/7.0

D42A/D42L 950/3.1 1250/4.7 1800/7.0

D48A/D48L 1100/3.8 1600/6.3 1800/7.0

D60A/D60L 1100/3.8 1600/6.3 1800/7.0

Manual 2100-643C Page 24 of 59

Same as

Free Cooling

Mode

Free Cooling Mode

TABLE 2.2

Blower Speed Voltage Chart

Free Cooling Mode

(CFM/VDC

Speed Voltage)

1500/6.0

Below 40°F

(CFM/VDC

Speed Voltage)

900/2.0 900/2.0 1100/4.0

Cooling

(CFM/VDC

Speed Voltage)

Electric Heat

• If conditions outside are not conducive to free cooling, the control board will send:

1. 24VAC signal from N02 to CCM (Compressor)

2. 24VDC from terminal N07 (Blower Motor Start

Relay)

3. 0-10VDC signal from Y1 (Speed Voltage)

Heating Call

When a call for heating generates from the controller, the control board will send:

1. 24VAC signal from terminal N04 to heat strip contactor.

2. 24VDC from terminal N07 (Blower Motor Start Relay)

3. 0-10VDC signal from terminal Y1 (Motor Speed)

FIGURE 2.2

Wall-Mount Unit Control Board

Loss of Utility Power

When AC power is lost to the unit (no shore power, no generator), the AC power loss relay will send a digital input to terminal DI 1, alerting the board. If the temperature outside is warmer than the shelter internal temperature, the units will remain static. If the temperature outside is cooler than the internal temperature and there is a generated cooling call, the control board will send:

1. 2-10VDC Signal from terminal Y2 (Damper Signal)

- Modulates damper to achieve 55°F at supply air temperature sensor

2. 24VDC from terminal N07 (Blower Motor Start

Relay)

3. 0-10VDC signal from terminal Y1 (Motor Speed)

High Pressure/Comp Control Module

Low Pressure Switch

Damper Blade Switch

Common

0-10VDC Indoor Blower Speed Signal

2-10VDC Free-Cooling Damper Signal

Power Loss Relay

Dirty Filter Switch

Common

24VDC to OA Humidity Sensor

Ground

Freezestat Sensor 10kΩ

OA Hum Sensor 4-20mA

RA Temp Sensor 10kΩ

OA Temp Sensor 10kΩ

Supply Air Sensor 10kΩ

–24VDC from Power Converter

+24VDC from Power Converter

24VDC from 48VDC-24VDC Converter

24VDC Output to Blower Motor Start Relay

24VAC Heating Output

24VAC Input

– Communication Wire

+ Communication Wire

24VAC Input

24VAC Compressor Output

Manual 2100-643C Page 25 of 59

Special Considerations

• Compressor Run Time – Once activated, the compressor will run for a minimum of 5 minutes, regardless of setpoint (control board programming)

• Compressor Off Time – Once deactivated, the compressor will not start again for a minimum of 2 minutes.

• 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 then send a digital input to the DI 3 terminal.

• Low Pressure Situation – The low pressure switch is connected directly to DI 4:

1. On a call for cooling, the board ignores the

low pressure switch status for 2 minutes (OAT above 50°F) or 3 minutes (OAT below 50°F).

2. If the switch is still open, the compressor

will shut down and the controller will wait an additional 2 minutes.

3. If the switch is still open, the controller will

notify of an alarm and lock out the compressor. However, if the switch closes during this time, the compressor will start again and wait for 2 minutes (OAT above 50°F) or 3 minutes (OAT below 50°F).

4. If the low pressure switch is open at this time,

the compressor will lock out and the controller will notify of an alarm.

• 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 – Should the hydrogen detector send an alarm signal to the controller, both free cooling dampers will open (regardless of temperature) to dilute the shelter air.

• Freezestat – If the coil temperature is below 30°F for 120 seconds, the compressor will deactivate for 5 minutes, or until the sensor sees 55°F, whichever comes ﬁrst.

• Generator Run – During generator operation, the system may limit compressor operation to only one unit providing that a speciﬁc jumper was removed from the LC controller terminal block and the alarm wires were connected to a generator-run relay (please refer to the Installation section of this manual regarding alarms and wiring).

Manual 2100-643C Page 26 of 59

FIGURE 2.3

TEC-EYETM Display

USING THE TEC-EYE

ALARM KEY

MENU KEY

ESCAPE KEY

ALARM KEY

Allows viewing of active alarms Silences audible alarms Resets active alarms

MENU KEY

Allows entry to Main Menu

ESCAPE KEY

Returns to previous menu level Cancels a changed entry

UP KEY

Steps to next screen in the display menu Changes (increases) the value of a modiﬁable ﬁeld

ENTER KEY

Accepts current value of a modiﬁable ﬁeld Advances cursor

DOWN KEY

Steps back to previous screen in the display menu Changes (decreases) the value of a modiﬁable ﬁeld

TEC-EYETM HAND-HELD DIAGNOSTIC TOOL

The microprocessor control used in this wall mount air conditioning system allows for complete control and monitoring through the use of the provided TEC-

EYE

hand-held monitor. This comprehensive service tool utilizes the latest in state-of-the-art technology including a large, easy-to-read backlit LCD graphic display.

The menu driven interface provides users the ability to scroll through three menu levels: Info, Control and Service. The menus permit the user to easily view, control and conﬁgure the unit.

The controller is completely programmed at the factory; therefore, most applications will require no ﬁeld set-up. However, the default setpoints and their ranges are easily viewed and adjusted from the TEC-EYE 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.

The TEC-EYE

connects to the wall-mount unit control board via an RJ11 modular phone connector as shown in Figure 2.4.

display.

UP KEY

ENTER KEY

DOWN KEY

The TEC-EYETM hand-held diagnostic tool should be stored somewhere inside the shelter, preferably close to

the controller. The TEC-EYE

has integrated magnets on the back of the tool, so it can be attached to the front, sides, bottom or top of the control box.

FIGURE 2.4

TEC-EYETM Connection to Unit Control

Modular Phone Connector for

TEC-EYE

Hand-Held Diagnostic Tool

Manual 2100-643C Page 27 of 59

TEC-EYETM Menu Structure

On/Off Unit Setpoints Clock/Scheduler Input/Output Analog Inputs Digital Inputs Relay Outputs Analog Outputs Alarm History Technician Information Working Hours Service Settings Control Loops Probe Adjustment Manual Management Analog Inputs Digital Inputs Relay Outputs Analog Outputs Factory Conﬁguration I/O Conﬁguration Factory Settings

In addition to the menu structure above, there are also Status and Alarm screens.

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 STATUS screen displays the current date, time, return air temperature, supply air temperature, outdoor air temperature, outdoor humidity and dewpoint conditions. It also indicates the current system operating status for Unit 1 (U1) or Unit 2 (U2). The screen displays whether the blower is off or on and what percentage the damper is open.

FIGURE 2.5

TEC-EYETM Status Display

TEC-EYE

Acronyms

SAT – Supply air temperature RAT – Return air temperature OAT – Outdoor air temperature OAH – Outdoor air humidity Sp – Temperature setpoint Space – Space temperature U1 – Unit 1 U2 – Unit 2 F – Indoor blower status D – DC free cooling damper position status EM – Emergency ventilation mode C1 – Compressor activate status HT – Heater status OA Dew Point – Calculated outdoor dew point FC – DC free cooling status RN – Component run time in minutes in last hour ST – Number of start requests in last hour

Press the MENU key to access the Main Menu screen. Press the UP or DOWN keys to scroll through the available menus. When the desired menu is highlighted, press the ENTER key to access that menu. Press the ESCAPE key or MENU key to return to the STATUS screen from the Main Menu.

For the following items, press the MENU key to access programming.

Executing a Run Test

Execute a run test on each unit to verify the equipment is functioning correctly.

1. Go to Technician menu, press ENTER key.

2. Press UP or DOWN arrow keys to get to Service Settings menu, press ENTER key.

3. Press UP or DOWN arrow keys to get to Control Loops menu, press ENTER key.

4. Cursor will 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.

Run Test Approximate Timings (in Minutes)

Blower On: 0:00 Damper Open: 0:00 – 2:40 Closed: 2:41 – 4:57 Compressor On: 4:58 Off: 6:00 Heat On: 6:01 Off: 7:10 Blower Off: 8:19

Manual 2100-643C Page 28 of 59

Identifying a Unit Address

1. Go to Setpoints menu, press ENTER key.

2. Press UP or DOWN arrow keys to get to Fieldbus Address, press ENTER key. The wall-mount unit's current address value will display.

NOTE: This value can be changed if there was an error with the Auto Address sequence or the user would like to manually set the address of the unit.

Manual Override Outputs

Blower

1. Go to Technician menu, press ENTER key.

2. Go to Manual Management, press ENTER key.

3. Go to Relay Outputs, press the DOWN arrow to get to Blower Relay Output. Move the cursor to the selected choice by pressing the ENTER key. Press UP or DOWN arrow keys to change the Manual Relay and Manual Position to “ON.”

4. Press ESCAPE key, go to Analog Outputs.

5. Go to Blower Motor Analog Output, press Enter key to move the cursor to Mode. Change to Hand by pressing the UP arrow key. Press ENTER key. Next change the Manual Value to test blower speed voltage for the unit model and press ENTER key. Refer to the unit blower speed voltages provided in Table 2.6 on page 40; do not exceed the maximum speed voltage (VDC) for the unit model.

DC Free Cooling Damper

1. Go to Technician menu, press ENTER key.

2. Go to Manual Management, press ENTER key.

3. Go to Analog Outputs, press ENTER key.

4. Press DOWN arrow key to scroll screens to Analog Output 2 Damper.

5. Press ENTER key to scroll 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 Cooling Stage. Press UP or DOWN arrow keys to change Manual Relay to “ON”; press ENTER key. Press UP or DOWN arrow keys to change manual position to “ON” and press ENTER key.

5. Verify compressor is running.

Heat

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 Heating, press ENTER key.

5. Press UP or DOWN arrow keys to change Manual Relay and Manual Position to “ON” and press ENTER key.

6. Verify heater “ON” status.

The Bard DC Free Cooling Unit System has been pre-programmed with what is widely considered to be the best settings for efﬁciency and operation. Any changes to internal programming through the LC Series Controller or the TEC-EYE 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 recommended.

CAUTION

not covered within this

Manual 2100-643C Page 29 of 59

COMPONENTRY SPECIFICATIONS

OUTDOOR TEMPERATURE/HUMIDITY

WARNING

Electrical shock hazard.

Disconnect both VAC and VDC power supplies

before servicing.

Failure to do so could result in electric shock or death.

LOW PRESSURE SWITCH

Cut-out pressure: 40psi (+/- 4 psi) Cut-in pressure: 55psi (+/- 4psi)

HIGH PRESSURE SWITCH

Cut-out pressure: 650psi (+/- 10 psi) Cut-in pressure: 520psi (+/- 15psi)

LOW AMBIENT CONTROL

Modulating head-pressure control that allows full speed at pressures above 315psi. Below 315psi, the control will slow fan speed—following internal head pressures—until a minimum RPM is reached (approx 300 RPM). Below this point, the control will shut the fan completely off until internal pressures rise. The control is preset from the factory, but should adjustment become necessary, there is an adjustment screw located on the bottom of the control behind a weatherproof cap. One full turn clockwise equals approximately +48 psi.

REMOTE INDOOR TEMPERATURE SENSOR

White, decorative plastic casing, Bard logo, ﬁeldinstalled in shelter: 10k ohm resistance, see Table 2.3.

DISCHARGE TEMP SENSOR

4.75” stainless probe factory mounted in supply opening of wall-mount unit: 10k ohm resistance, see Table 2.3.

RETURN TEMPERATURE SENSOR

Exposed thermistor-element style with copper-coated steel clip, attached in return opening of wall-mount unit: 10k ohm resistance, see Table 2.3.

EVAPORATOR TEMP SENSOR (FREEZESTAT)

Exposed thermistor-element style with copper-coated steel clip, attached to evaporator coil of wall-mount unit: 10k ohm resistance, see Table 2.3.

SENSOR

Gray, weather-proof octagonal case with dip tube, located in condenser section of wall-mount unit.

• Temperature sensor: 10k ohm resistance, see Table

• Humidity sensor: 4-20mA.

COMPRESSOR CONTROL MODULE

Compressor protection device that has an adjustable 30-second to 5-minute timer (red-dial). This module features a delay-on-make for initial start-up (or anytime power is interrupted) for a minimum 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 terminal on the CCM will become active with 24V, which will power the high pressure relay within the wall-mount unit, breaking a digital input to the control board—signaling a high-pressure situation to the system.

PHASE MONITOR

Used only on 3-phase equipment, the phase monitor is a compressor protection device that will prohibit operation of the compressor if the device senses a possible reverse-rotation situation due to incorrect phasing. On a call for compressor (and only compressor), the device will check incoming phase, check for severe voltage imbalance and check for proper frequency. Under nominal conditions, a green LED light will show on the face of the monitor. If there is improper phasing, voltage imbalance or frequency deviation, the device will show a red LED light and prohibit compressor operation.

TRANSFORMER

75VA with external 4A circuit breaker, 230VAC/208VAC convertible. Directly feeds power loss relay in wallmount unit during normal operation. Should loss of utility power occur, transformer failure or transformer external circuit breaker open, the loss of VAC power will cause the contacts within the power loss relay to open, interrupting a digital input to the control board— signaling a loss-of-power situation to the system.

2.3.

Manual 2100-643C Page 30 of 59

TABLE 2.3

Temperature (F) vs. Resistance (R) of Temperature Sensor

F R F R F R F R

-25.0 196871 13.0 56985 53.0 19374 89.0 7507

-24.0 190099 14.0 55284 52.0 18867 90.0 7334

-23.0 183585 15.0 53640 53.0 18375 91.0 7165

-22.0 177318 16.0 52051 54.0 17989 92.0 7000

-21.0 171289 17.0 50514 55.0 17434 93.0 6840

-20.0 165487 18.0 49028 56.0 16984 94.0 6683

-19.0 159904 19.0 47590 57.0 16547 95.0 6531

-18.0 154529 20.0 46200 58.0 16122 96.0 6383

-17.0 149355 21.0 44855 59.0 15710 97.0 6239

-16.0 144374 22.0 43554 60.0 15310 98.0 6098

-15.0 139576 23.0 42295 61.0 14921 99.0 5961

-14.0 134956 24.0 41077 62.0 14544 100.0 5827

-13.0 130506 25.0 39898 63.0 14177 101.0 5697

-12.0 126219 26.0 38757 64.0 13820 102.0 5570

-11.0 122089 27.0 37652 65.0 13474 103.0 5446

-10.0 118108 28.0 36583 66.0 13137 104.0 5326

-9.0 114272 29.0 35548 67.0 12810 105.0 5208

-8.0 110575 30.0 34545 68.0 12492 106.0 5094

-7.0 107010 31.0 33574 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 9760 116.0 4093

3.0 77632 41.0 25383 79.0 9526 117.0 4006

4.0 75230 42.0 24696 80.0 9299 118.0 3921

5.0 72910 43.0 24030 81.0 9077 119.0 3838

6.0 70670 44.0 23384 82.0 8862 120.0 3757

7.0 68507 45.0 22758 83.0 8653 121.0 3678

8.0 66418 46.0 22150 84.0 8449 122.0 3601

9.0 64399 47.0 21561 85.0 8250 123.0 3526

10.0 62449 48.0 20989 86.0 8057 124.0 3452

11.0 60565 49.0 20435 87.0 7869

12.0 58745 50.0 19896 88.0 7686

BATTERIES

Used in wall-mount unit and controller boards, ﬂatdisk style BR2330 3V battery. Used only for time/date during complete power loss. Estimated lifespan 7-8 years.

48VDC TO 24VDC POWER CONVERTER

Used in both wall-mount units and LC-Series controller to change shelter-provided 48VDC to 24VDC power for control boards, relays, smoke detector and hydrogen detector: Phoenix Quint PS-Series. NOTE: Output must

be minimum 22.8 VDC to allow proper control board operation.

Manual 2100-643C Page 31 of 59

OUTDOOR FAN MOTOR

"A"

AIRFLOW

MIS-1724

Due to design considerations of the condenser section of the wall-mount unit, placement/clearance of the motor/fan blade is critical to heat dispersal. Should a change of motor or fan blade be necessary, please view Figure 2.6 for proper clearance adjustment.

DIRTY FILTER SWITCH

Located inside the blower compartment, this switch measures air pressure differential across the ﬁlter (see Figure 2.7). Manual reset only. Default setting: 0.8" static, 50% blocked ﬁlter (approximately).

INDOOR BLOWER MOTOR

Unlike most other system fan motors, this motor is a 48VDC motor, and is very specialized in application. Please see Table 2.4 (blower table).

PHOENIX ISOLATION RELAY: WALL-MOUNT UNIT

Green DIN-Rail mount isolation relay used in the wallmount unit to isolate/ﬁlter 48VDC power, motor speed signal and ground from the control board: Phoenix Mini MCR-Style.

FIGURE 2.6

Fan Blade Setting

Model Dimension A

All covered by

this manual

FIGURE 2.7

Dirty Filter Switch

1.75"

ZETTLER ISOLATION RELAYS: WALL-MOUNT UNIT

Black Zettler surface mount relays used in the wallmount unit to isolate the start signal from:

Power loss relay circuit (see Figure 2.8)

•

• High pressure relay circuit (see Figure 2.9)

• Blower motor start signal relay circuit (see Figure

2.10)

TABLE 2.4

Indoor Blower Performance

MODEL

D25A/D25L 0.15 0.50 1500 800 800 1100

D28A/D28L 0.10 0.50 1800 800 1100 1800

D35A/D35L 0.15 0.50 1500 800 1100 1100

D36A/D36L 0.15 0.50 1800 800 1100 1800

RATED

ESP

MAX ESP

FREE COOLING

CFM ABOVE 40°

FREE COOLING

CFM BELOW 40°



RATED

FULL LOAD

COOLING CFM

ELECTRIC

HEAT

AIRFLOW

D42A/D42L 0.20 0.50 1800 950 1250 1800

D48A/D48L 0.20 0.50 1800 1100 1600 1800

D60A/D60L 0.20 0.50 1800 1100 1600 1800

 LC Series controller derives at this decision point and switches the indoor motor speed. The damper actuator will then

adjust to still yield a 55°F supply air temperature.

Manual 2100-643C Page 32 of 59

FIGURE 2.8

Power Loss Relay Circuit

FIGURE 2.9

High Pressure Relay Circuit

Blower Motor Start Relay

FIGURE 2.10

Blower Motor Start Relay Circuit

Manual 2100-643C Page 33 of 59

CABLE DUCT

DC CONVERTOR

FIGURE 2.11

D25A/L, D35A/L Unit Control Panel

DC POLARITY VOLTAGE MONITOR

CONTROL PANEL

2 POLE CONTACTOR 20 AMP

FILTER

SWITCH

ASSEMBLY

SPDT RELAY

24 VDC COIL

SNAP BUSHING

TERMINAL BLOCK

SPDT RELAY

TERMINAL BLOCK

DC CIRCUIT BREAKER

CIRCUIT BREAKER BASE

TERMINAL BLOCK

LABELS

CIRCUIT BREAKER

CIRCUIT BREAKER MOUNTING FOOT

DIN RAIL END CLAMP TERMINAL BLOCK TERMINAL

PLC CONTROLLER

END CLAMP

RS485 LABEL

SOFTWARE

PAPER LABEL

COMPRESSOR

CONTROL MODULE

MOTOR STARTING

DEVICE

PTCR MTG

BRACKET

CAPACITOR

BRACKET

Manual 2100-643C Page 34 of 59

CAPACITOR

WIRE SHIELD

TRANSFORMER

2 POLE CONTACTOR 40 AMP

MIS-3847

BREAKER

CIRCUIT

DUCT TRANSFORMER

CABLE

20 AMP

CONTACTOR

2 POLE

MONITOR

VOLTAGE

BREAKER BASE

CIRCUIT

EVAP. TEMP. SENSOR

TERMINAL

GROUND

BREAKER

SWITCH

TERMINAL BLOCK

DC CIRCUIT

DC POLARITY

CABLE DUCT

RS485 LABEL

DIN RAIL

END CLAMP

TERMINAL BLOCK

SHEATHED CABLE

WIRE SHIELD

DEVICE

MOTOR STARTING

BRACKET

CAPACITOR

PANEL

CONTROL

BLOCK

TERMINAL

CONTROLLER

PLC

MODULE

ISOLATION

COMMON

40 AMP

END CLAMP

"L1"

CONTACTOR

CONTROL MOD.

COMPRESSOR

CONTROL MOD.

COMMON

START RELAY

BLOWER MOTOR

RELAY

POWER LOSS

HARNESS

WIRE

2 POLE

ASSEMBLY

DC CONVERTER

LABELS

FILTER

COMPRESSOR RELAY

D28A/L, D36A/L, D42A/L, D48A/L, D60A/L Unit Control Panel

FIGURE 2.12

MIS-3671

Manual 2100-643C Page 35 of 59

4206-114 A

MOTOR POWER

Black/Gr een

Pink

Black/Gr een

102

BLOWER

MOTOR

Pink

Black/Gr een

ANALOG GROUND TERMINAL

Green

Orange

OAT

Orange

Black/W hite

44 45

MODULE

COMPRESSOR CONTRO L

HPCRY

YELLOW

BLUE BLUE

BROWN

COMP. RELAY

COM

Black/White

COM

Power Loss

Relay

Black/White

COM

Blower Relay

Outdoor temp

and humidity sensor

OAH

Orange

4-20 m A

V IN

Orange

Blue

Black/Green

Orange

ALR

103

PLUG

RED

WHITE WHITE BLACK

RED

5 3 2 1 23 1

MOTOR POWER PLUG

Orange

Green

Supply Air

Sensor

White

VOUT

COM

Black Red

Dirty Filter Switch

LOW

PRESSURE

SWITCH

100101

EVAP. TEMP.

SENSOR

DIGITAL GROUND TERMINAL

Yellow/Red

Black/White

MINUTES

LPC

Red/White

Yellow

FIGURE 2.13

D25A/L, D35A/L Unit Wiring Diagram

RED

BLACK

RED

YELLOW

ORANGEORANGE

BROWN

Red/Blac k

Red

Red/Whi te

MOTOR

CONTROLLER

BLACK

RED

MOTOR

8 21345679

PLUG

Orange

129

Red/Whi te

127

129

Red

Black

Red

Black

Orange

Orange/Bl ack

Black/Red Orange

129

Red/Blac k

Red

Black/Red

Orange

Pink

48 76 49 99 50 32 52 54

Orange/Black

Blue

111 112 113 106 115

Connector

127

Red/White

PROGRAMMABLE LOGIC CONTROL

111 111106

Connector

Orange/Black

Connector

Black/Green

Yellow

Red/White

131

L1 L2

Auxiliary

NC Contact

T1 T2

Blue

BLUE

LOW AMBIENT

Black/White

CONTROL

Outdoor Fan Motor (see chart)

Compressor

Contactor

BROWN

YELLOW

BLACK

Black/Red

Red

Black/White

116

RED

YELLOW BROWN

Black

BLACK

Red

929393

Connector

Red/White

Compressor

Yellow

Red

Black/R ed

100

Connector

White

Black/Green

T R A N S F O

R M E R

Start Kit

F A

Red/Black

Black

109 110

Connector

122

Brown

YELLOW

Yellow

R E H

CAPACITOR

SECONDARY

LIMIT

Brown

5 KW HEAT STRIP

PRIMARY

LIMIT

BLACK/WHITE

25 63

L2 L1

HEATER CONTACTOR

RED

BLACK

T2 T1

White

Red

Black/Red

Connector

Red

Red/Black

Black

Black/R ed

Orange/Bl ack

Connector

White

119119

Black

240V

COM

208V

COMPRESSOR CRANK CASE HEATER (OPT.)

116

High Voltage

Low Voltage

Factory Opt ionalField

39 50

Female Side

RED

Circuit Breaker

Red

Terminal Block

NC NO

PWR

POL

FAULT

GOOD

140

COM

PWR (Green) DC power ON and within range (48-58v) POL (Yellow) DC polarity is correct, DCV output active Fault (Red) DC polarity is correct, reverse FIELD connection

48 Vdc to 24 Vdc

BlackRe d

VENT PLUG

DBS/RAS

PLUG

Converter

ADJ.

Output

Input

Com2+3Y5U

1 432

21 3 4

Damper Actuator Motor

24 Vac/Vdc

BLACK

Male Side

POLARITY

MONITOR

x x x x x

2....10 Vdc

DAMPER BLADE SWITCH

Black/Red

Red/Blac k

FOR 208 OPERATION MOVE THIS RED WIRE TO 208 VOLT TRANSFORMER TAP

208/23 0-60-1

137

138

Black

134

52 Vdc

139

NC NO

COM

133

Red

Black

129

RED

WHITE

Green

Return Air

Sensor

48 VDC

24 VDC

0-10 VDC

Manual 2100-643C Page 36 of 59

FIGURE 2.14

COM

NCNO

Start Kit

Yellow

Fan Motor

Outdoor

(see chart)

Compressor

2....10 Vdc

24 Vac/Vdc

Com2+3Y5U

Damper Actuator Motor

48 Vdc to 24 Vdc

Output

Input

x x

ADJ.

Converter

208V

COM

240V

Circuit Breaker

208/23 0-60-1

Supply Air

Sensor

COM

HPCRY

ALR

MINUTES

LPC

OAT

OAH

4-20 m A

V IN

COM

VOUT

L1 L2

21 3 4

Return Air

Sensor

1 432

COM

PWR (Green) DC power ON and within range (48-58v) POL (Yellow) DC polarity is correct, DCV output active Fault (Red) DC polarity is correct, reverse FIELD connection

COM

NC NO

COM

PWR GOOD

POL

GOOD

FAULT

8 21345679

MOTOR PLUG

Blue

BLUE BLUE

WHITE WHITE

Pink

YELLOW

Yellow

YELLOW

Yellow

Yellow/Red

YELLOW

Orange

ORANGE

and humidity sensor

DAMPER BLADE SWITCH

Orange

Orange/Bl ack

Orange

Outdoor temp

ORANGE

Brown

BROWN

Brown

BROWN

3 1

RED

O R A N G E

B L U E

B L A C K

RED

R E D

PLUG

BLACK

Green

WHITE

RED

CAPACITOR

MOTOR

VENT

RED

COMPRESSOR

(OPT.)

RED

BLUE

BROWN

BLACK

YELLOW

BLACK

BROWN

CRANK CASE

RELAY

YELLOW

SECONDARY

LIMIT

5 KW HEAT STRIP

T R A N S F O R M E R

LIMIT

PRIMARY

CONTROL

L2 L1

HEATER CONTACTOR

LOW AMBIENT

HEATER (OPT.)

CONTROLLER

Low Voltage

High Voltage

Factory Opti onal

Field

COMP. CCH

Compressor

Contactor

COMPRESSOR CONTRO L

MODULE

44 45

42 63

Red

Red/Blac k

Red

Red/White

Red/Whi te

Red/White

Red

Red/Black

125

126

48 76 49 99 50 47 52 53

Orange/Black

Red

MOTOR POWER

Red/White

MOTOR

DBS/RAS

PLUG

929393

100101

102

103

107 107106

109 110

111 112 113 106 115

Red/White

116

White

Red

122

119119

100

FOR 208 OPERATION MOVE THIS RED WIRE TO 208 VOLT TRANSFORMER TAP

128

129

Red

126

125

127

128

129

131

Orange/Bl ack

127

White

52 Vdc

131

Red

124

139

Terminal Block

134

POLARITY

MONITOR

133

137

Red

138

Red

48 VDC

24 VDC

PLUG

RED

0-10 VDC

MOTOR POWER

PLUG

RED

140

BLOWER

RED

GROUND

BLACK

Orange

GROUND TERMINAL

Dirty Filter Switch

BLACK/WHITE

Black

SWITCH

ANALOG

PRESSURE

COMP. RELAY

LOW

Power Loss

Red/Black

SENSOR

TERMINAL

Relay

RELAY

Black/Green

White

DIGITAL

EVAP. TEMP.

4206-106 G

Black/W hite

Black/White

Black/Gr een

Black/Green

Black

BlackRe d

Black

Black/Gr een

Black/White

Black/Red

Black

Black/R ed

Black/Green

Male Side

Black/White

Connector

Black

Green

Black/Red Orange

Black/White

Orange

Female Side

Black

PROGRAMMABLE

Black/Red

Red/White

LOGIC CONTROL

Black/R ed

Red/Black

Black/Red

Black/R ed

Black/Red

Red/Blac k

Black

Blower Relay

Orange

Orange/Black

Black/Gr een

Black

ANALOG ISOLATION

BLACK

D28A/L, D36A/L, D42A/L, D48A/L, D60A/L Unit Wiring Diagram

Manual 2100-643C Page 37 of 59

MAINTENANCE AND TROUBLESHOOTING

STANDARD MAINTENANCE PROCEDURES

WARNING

Electrical shock hazard.

Disconnect both VAC and VDC power supplies

before servicing.

Failure to do so could result in electric shock or death.

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp edges.

Failure to do so could result in personal

injury.

1. Disable system from LC controller (see controller manual).

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 assembly from the condenser section. This will give clear access to the inlet side of the coil for cleaning. Follow the coil cleaner manufacturer’s directions for necessary safety gear and precautions, as well as for application and use. More than one application may be necessary. Rinse thoroughly.

• Evaporator coil: Remove the evaporator

section panel and apply speciﬁc evaporator cleaner directly to the inlet side of coil, being very careful not to overspray into insulation or surrounding panels and wiring. Residual cleaner and dissolved debris should drip into the drain pan and leave the unit through the condensate hose. More than one application may be necessary. Rinse thoroughly.

4. Manually spin fan and blower motors to ensure they turn freely. All motors are permanently lubricated, so no oil is necessary.

5. Inspect free cooling damper actuator and linkage.

6. Install new air ﬁlter; check for additional ﬁlter grilles internal to the structure.

7. Inspect the control panel of the system.

• Look for insect or rodent activity and remove

any nesting materials.

• Manually push contactor closed, observe for

movement—contactor points should have minimal discoloration, no spalling or other signs of arcing. Replace if doubtful.

• Check ﬁeld and factory wiring for tightness and

look for signs of overheating (discoloration of terminals or wire insulation).

8. Ensure that supply and return registers are not obstructed, and more importantly, are not recycling the air to one another. Adjust supply louvers if necessary to direct discharge air away from any direct route to the return grille.

9. Re-assemble wall-mount unit and turn breakers back on.

10. Enable system from LC controller (see controller manual).

11. Repeat steps for second wall-mount unit.

Manual 2100-643C Page 38 of 59

SPECIFIC TROUBLESHOOTING – 48VDC 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,

TABLE 2.5

Troubleshooting the 48VDC Indoor Blower Motor

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 items in Table 2.5 (see Figure

2.15 below and Figures 2.16 and 2.17 on page 40).

Motor Controller

Molex Plug

1 Red SPEED INPUT

4 Orange RUN

7 Red 52 VDC (+) "+" VDC power supplied to motor

9 Black 52 VDC (-) "-" VDC power supplied to motor

Color Function Description of Application

0-10 VDC input, varying voltage input between 0-10 VDC dictates the motor speed/ CFM delivery

Start Command – a contact closure between this wire and the control ground (Pin 5) will issue and order for the motor to start.

Black CONTROL GROUND

Control Ground for both start-stop function and speed control voltage

FIGURE 2.15

Troubleshooting Motor Power Supply

Motor Power Supply: With the meter set to VDC, place

the black (–) lead on Pin 9 and the red (+) lead on Pin 7 of the female portion of the Molex-style plug connecting the motor controller to the back of the wall-mount control cabinet. Nominal voltage should be 48VDC to 54VDC.

Note the plug-pin "ﬂats" for proper orientation of the plug.

48VDC

Female Plug

Manual 2100-643C Page 39 of 59

< 1Ω

FIGURE 2.16

Troubleshooting Motor Start Command

Motor Start Command: With the meter set to Continuity Beeper,

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

FIGURE 2.17

Troubleshooting Speed Voltage

Speed Voltage: With the meter set to VDC, place the black (–) lead

on Pin 5 and the red (+) lead on Pin 1 of the female portion of the Molex-style plug connecting the motor controller to the back of the wall-mount control cabinet. Nominal voltage should be 2.8VDC to 7VDC. Reference Table 2.6 for exact voltage.

Note the plug-pin "ﬂats" for proper orientation of the plug.

???VDC

Female Plug

TABLE 2.6

Blower Speed Voltage Chart

Model Blower Only

D25A/D25L

D28A/D28L 800/2.8 1100/3.8 1800/7.0

D35A/D35L 1100/3.0 1100/4.0 1100/4.0

D36A/D36L 800/2.8 1100/3.8 1800/7.0

D42A/D42L 950/3.1 1250/4.7 1800/7.0

D48A/D48L 1100/3.8 1600/6.3 1800/7.0

D60A/D60L 1100/3.8 1600/6.3 1800/7.0

Same as

Free Cooling

Mode

Free Cooling Mode

(CFM/VDC

Speed Voltage)

1500/6.0

Free Cooling Mode

Below 40°F

(CFM/VDC

Speed Voltage)

900/2.0 900/2.0 1100/4.0

Cooling

(CFM/VDC

Speed Voltage)

Electric Heat

Manual 2100-643C Page 40 of 59

FIGURE 2.18

VDC Polarity Check

Bard System

Supply Breakers

Step 1

Multimeter set to VDC:

Display reveals "0" voltage potential

Step 2

Multimeter set to VDC:

Positive-to-ground reveals

"0" voltage potential

Shelter VDC Power Supply

-48VDC, Positive Ground

0 VDC

Shelter VDC Power Supply

-48VDC, Positive Ground

Bard System Supply Breakers:

VDC breaker in OFF position

0 VDC

Shelter VDC Power Supply

-48VDC, Positive Ground

Bard System Supply Breakers:

VDC breaker in OFF position

Step 3

Multimeter set to VDC:

Negative-to-ground reveals

"-48" voltage potential

Bard System Supply Breakers:

VDC breaker in OFF position

-48 VDC

Shelter VDC Power Supply

-48VDC, Positive Ground

Manual 2100-643C Page 41 of 59

FIGURE 2.19

Verifying Incoming Voltage: VDC

Multimeter set to VDC

52VDC

48VDC Shelter System

Voltage Range:

40VDC – 56VDC

Typical Running Range:

48VDC – 53VDC

Shelter supply breaker in ON position

Bard system breaker in OFF position

Displayed voltage must be within this range

Manual 2100-643C Page 42 of 59

TROUBLESHOOTING WALL-MOUNT UNIT ALARMS

In the event that a problem is encountered with a wall-mount unit, the TEC-EYETM hand-held tool may be used to diagnose the cause. Department at 419.636.0439 for assistance.

If the problem can’t be resolved using these guidelines, contact the BARD Technical Service

Signal Description Possible Cause Component to Check Recommended Action

Low Pressure Alarm

High Pressure Alarm

Landline/Shore/ Prime Power Outage

Dirty Air Filter Alarm

DC Free Cooling Damper Fails to Open Alarm

Alarm is activated when a low pressure event is present in the refrigeration system and the compressor is running.

If the alarm activates once or twice in an hour, it is reset automatically. If it occurs three times in an hour, the compressor and condenser fan are locked.

Alarm is reset automatically.

The alarm is a warning to check the ﬁlter. Alarm can only be reset manually.

Alarm is reset automatically.

Lack of refrigerant

The switch is defective.

Check if the connection to the corresponding input terminal is ok or if the controller board is defective.

Abnormal site condition

Condenser fan has failed. The condenser fan speed controller has failed.

The switch is defective.

Check if the connection to the corresponding input terminal is ok or if the controller board is defective.

Primary power has gone off.

Filter is clogged.

Check if the connection to the corresponding input terminal is OK or if the controller board is defective.

The value set for the differential air pressure switch is too low.

DC free cooling damper fails to open.

Run the unit and check if the low pressure value is in the normal range.

Check if the pressure switch is OK.

Check if the connection is OK. Check is the controller board is OK.

Check open door or for abnormal site condition. Check if the high pressure value is in the normal range.

Check the condenser fan status while the high pressure is outside the normal setting.

Check if the high pressure switch is OK.

Check if the connection is OK. Check is the controller board is OK.

Check if the ﬁlter is dirty.

Check if the connection is OK.

Check the differential air pressure switch value.

Check the damper linkage. Check to see if anything is in the way of the damper.

Charge appropriate amount of refrigeration.

If defective, replace.

Reconnect the cables. If the controller board is defective, replace.

Clean the condenser.

Replace the condenser fan. Replace the condenser low ambient (fan speed) controller.

If defective, replace.

Reconnect the cables. If the controller board is defective, replace.

Clean or replace the ﬁlter.

Reconnect the cable. If the controller board is defective, replace.

Correct the value of the switch to standard value.

Device

Actions

Compressor/ Condensor Fan: Off

Indoor Blower: On Compressor/ Condensor Fan: Off Heat: Off Damper: On

Indoor Blower: On Damper: Off

Manual 2100-643C Page 43 of 59

TROUBLESHOOTING WALL-MOUNT UNIT ALARMS (CONT.)

Signal Description Possible Cause Component to Check Recommended Action

DC Free Cooling Damper Fails to Close Alarm

Communication Failed Alarm

Supply Air Temperature Sensor Failed Alarm (B01)

Outdoor Temperature Sensor Failed Alarm (B02)

Alarm is reset automatically.

The alarm is activated if the sensor is faulty, a sensor wire is loose or an out-of-range value is read.

DC free cooling damper fails to close.

Communication is lost with the LC Series main controller.

The alarm is activated if the sensor is faulty, a sensor wire is loose or an out-of-range value is read.

Check the damper linkage. Check to see if anything is in the way of the damper.

Check the RS485 port. Check for damage to the communications cable between the controllers.

Check the supply air temperature sensor wiring.

Check temperature vs. resistance of temperature sensor (see Table 2.3 on page 31).

Check the outdoor temperature sensor wiring.

Check temperature vs. resistance of temperature sensor (see Table 2.3 on page 31).

Reconnect the communications cable. If the controller board RS485 port is defective, replace.

Replace the supply air temperature sensor.

Replace the outdoor temperature sensor.

Device

Actions

Indoor Blower: On Damper: Off

Outdoor Humidity Sensor Failed Alarm

(B05)

Return Air Temperature Sensor Failed Alarm (B03)

The alarm is activated if the sensor is faulty, a sensor wire is loose or an out-of-range value is read.

Check the humidity sensor wiring.

Check the return air temperature sensor wiring.

Check temperature vs. resistance of temperature sensor (see Table 2.3 on page 31).

Replace the humidity sensor.

Replace the return air temperature sensor.

NEED ASSISTANCE?

This document contains the most current product information as of this printing. For the most up-to-date product information, go to www.bardhvac.com where there are links to product speciﬁcations, installation instructions, replacement parts manuals and wiring diagrams. Should any assistance be required during the installation or servicing of this product, contact the Bard Technical Service Department at 419.636.0439.

Manual 2100-643C Page 44 of 59

SECTION 3:

APPENDIX

Manual 2100-643C Page 45 of 59

WALL-MOUNT UNIT ARCHITECTURE

CAUTION: The Bard DC Free Cooling Unit System has been pre-programmed with what is widely considered to be the best settings for efﬁciency and operation. Any changes to internal programming through the LC Series controller or the TEC-EYE internal damage to the HVAC units, cause the shelter to overheat or other very serious consequences. Although complete controller programming architecture for the wall-mount unit controller has been provided, going outside the boundaries of what has been covered in this manual not recommended.

Screen Menu Item Range Default Value Description

MAIN STATUS SCREEN

The Status screen is the default screen on startup, and anytime more than 5 minutes has elapsed from last change. (Use UP/DOWN keys to scroll)

RAT °F Current return air temperature

SAT °F Current supply Air temperature

OAT °F Current outdoor air temperature

OAH % Current outdoor air humidity

Dewpoint °F Current temperature of dewpoint

Blower Off/On Displays status of blower

Damper % Displays percentage of current opening

Master Control Master Control

Status Unit On

MAIN MENU

Main Menu screen(s) allows access to operational programming, access by pressing MENU key at any time. (MENU key to enter, use UP/DOWN keys to scroll)

ON/OFF UNIT

Unit Address 1 Physical address of controller

Power by Display On/Off On

Status Blower

End of ON/OFF UNIT

SETPOINTS All setpoint changes are limited to 60 minutes

Cooling Setpoint 65°F – 90°F 77°F

Heating Setpoint 52°F – 75°F 60°F

Cooling Stg. Diff. 1°F – 5°F 5°F

Heating Stg. Diff. 1°F – 5°F 2°F

FreeCool

DC OA-Return Diff. 0°F – 99.9°F 7°F

Supply Temp Low Limit 28°F – 65°F 35°F

Differential 0°F – 99.9°F 20°F

Damper Time 0-999 150 seconds

Runtest Time 0-999 60 seconds

Freeze Temp Low Limit 0°F – 99.9°F 30°F

not covered within this manual may cause the systems to operate improperly, cause

Displays current data

Current operational status, "Running Stand Alone" if communication lost

D-Series controller board is currently

55°F, 57°F,

59°F, 61°F

active, "Off by Keyboard" if disabled by TEC-EYE

"OFF by Keyboard" system has been turned off at controller

55°F

Time alloted before damper fail is realized

Temperature sensed by Freezestat which initiates compressor shutdown

Manual 2100-643C Page 46 of 59

Screen Menu Item Range Default Value Description

Reset Temperature 0°F – 99.9°F 55°F

Reset Time 0-999 300 seconds

Temperature sensed by Freezestat which cancels compressor shutdown

Time alloted which will also cancel compressor shutdown

Blower Settings

Continuous None/Both/Lead None

Blower Speeds

Heat 0.0 – 7.6V 7.0V

Control voltage supplied from wall-mount unit control boards to blower in heat

Control voltage supplied from wall-mount

Econ 0.0 – 7.6V 7.0V

unit control boards to blower in regular DC free cooling

Control voltage supplied from wall-mount

Econ Low Temp 0.0 – 7.6V 3.8V

unit control boards to blower in low ambient condition DC free cooling

Control voltage supplied from wall-

Full Load 0.0 – 7.6V 6.3V

mount unit control boards to blower in mechanical cooling

Low Pressure Setup

Outside Setpoint 0°F – 99.9°F 55°F

Differential 0°F – 9.9°F 5°F

Temperature at which control separates two (2) different low pressure situations

This differential applies to the outside setpoint

Any low pressure situation above the

Above Setpoint Delay 0-999 120 seconds

outside setpoint will be delayed 120 seconds before an alarm is initialized

Any low pressure situation below the

Below Setpoint Delay 0-999 180 seconds

outside setpoint will be delayed 180 seconds before an alarm is initialized

Time btwn 2 1p 0-999 15 minutes

Fieldbus Address 0-999 11

Compressor Timers

Minimum Off 0-999 120 seconds

Minimum On 0-999 300 seconds

Comp Stage Delay 0-999 60 seconds

Once stopped, the compressor remains inactive for this period of time

Once started, the compressor remains on for this period of time

Minimum run time for ﬁrst stage of twostage compressors

Modulating Setup

Damper

DIR/REV Both

Cntrl: DIR P+1 P/P+I/PID

Band 0-999 75

Deadband 99.9 0

Int. 0-999 120 seconds

Minimum 0-999 0

Manual 2100-643C Page 47 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Maximum -1000 – 1000 1000

Period 500 – 9999mS 500mS

End of SETPOINTS

CLOCK/SCHEDULER

Clock

Time

Date (Current date)

Hour 1:00 – 24:00 (Current time)

Day Mon. – Fri.

Daylight Savings Time Enable/Disable Enable

Transition Time 0-240 60 minutes

Start:

End: F in at 0.00 - 12.00

End of CLOCK/SCHEDULER

INPUTS/OUTPUTS

Analog Inputs

Supply Air Temp Input B001

Outdoor Air Temp Input B002

Return Air Temp Input B003

Outdoor Humidity Input B005

Freezestat Input B007

Digital Inputs

Power Loss DI 1 Status Open

Filter Switch DI 2 Status Open

High Pressure Switch DI 3 Status

First, Second,

Third, Fourth,

Last

Sunday –

Saturday

January –

December

0:00 – 12:00 2:00

irst, Second,

Third, Fourth,

Last

Sunday –

Saturday

January –

December

0:00 – 12:00 3:00

(Current day of

week)

System clock will follow DST Protocol, "Disable" if desired

Last

Sunday

March

Last

Sunday

October

(Current SAT)

(current OAT)

(Current RAT)

(Current %RH)

(Current

Freezestat temp)

Open

Manual 2100-643C Page 48 of 59

Screen Menu Item Range Default Value Description

Low Pressure Switch DI4 Status

Open

Blower DI 5 Status Open

Damper Switch DI 6 Status

Open

Relay Outputs

Cooling Stage 1 Relay 2 Status

Cooling Stage 2 Relay 3 Status

Off

Heating Relay 4 Status Off

Blower Relay 7 Status Off

Analog Outputs

Analog Output 1 Blower Motor

0.00vdc

Analog Output 2 Damper 2.70vdc

End of INPUTS/OUTPUTS

ALARM HISTORY

020: Damper Close Fail

Supply Air

Outdoor Air

Return Air

Outdoor Humidity

Blower Speed

Damper Position

End of ALARM HISTORY

TECHNICIAN

Information

Bard Code

-3276.8 –

3276.7

Unit Controller

Version 0-99 1.20

Bios 0-99 6.33

Boot 0-99 4.05

FLSH 2048 9999 Internal memory speciﬁcations

RAM 512 999

0MB 0-9

T memory writes 0-32767

4.8 cycle/s 0-9999

Power Cycle Status

Last On Time 0-99

Last Off Time 0-99

Length Time Off 0-32767

Days: ### Hrs: ### Min: ###

32767/32767/

32767

Manual 2100-643C Page 49 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Working Hours

Run Hours

Compressor

Run Hours

Num Starts

Compressor Full Load

Run Hours

Num Starts

Free Cool

Run Hours

Num Starts

Heat

Run Hours

Num Starts

Blower

Run Hours

Num Starts

Service Settings

Control Loops

Modulating Setup Damper

Input 0-999

Output 0-9 0

Setpoint 0-99.9 55

Band 1.0 – 999.9 75

Integration Time 1-999 120

Delays

Damper Alarm Delays

Fail to Open 0 – 999s 20s

Fail to Close 0 – 999s 300s

Freezer Start 0 – 999s 120s

Freecoll Cp 0 – 999s 90s

Run Test

Run Test Time 0 – 999s 60s

Enable Yes/No No

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

Hours of operation

Number of starts

Hours of operation

Number of starts

Hours of operation

Number of starts

Hours of operation

Number of starts

Hours of operation

Number of starts

Manual 2100-643C Page 50 of 59

Screen Menu Item Range Default Value Description

Language

Language 0-1 English

Probe Adjustment

Analog Inputs

SAT Input B001

Offset -9.9 – 9.9 0

Value

-3276.8 –

3276.7

OAT Input B002

Offset -9.9 – 9.9 0

Value

-3276.8 –

3276.7

RAT Input B003

Offset -9.9 – 9.9 0

Value

-3276.8 –

3276.7

Outdoor Air Humidity Input B005

Offset -9.9 – 9.9 0

Value

Freezestat Input B007

-3276.8 –

3276.7

Offset -9.9 – 9.9 0

Value

-3276.8 –

3276.7

Manual Management

Analog Inputs

Supply Air Temp

Manual Control B001 Off/On Off

Manual Position -1000 – 1000 0

Value (Temp + Value)

On to manually change temperature seen by controller

Degrees of change in sensor for manual control

Current temperature plus the value in manual position

Outdoor Air Temp

Manual Control B002 Off/On Off

Manual Position -1000 – 1000 0

Value (Temp + Value)

On to manually change temperature seen by controller

Degrees of change in sensor for manual control

Current temperature plus the value in manual position

Manual 2100-643C Page 51 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Return Air Temp

Manual Control B003 Off/On Off

Manual Position -1000 – 1000 0

Value (Temp + Value)

Outdoor Humidity

Manual Control B005 Off/On Off

Manual Position -1000 – 1000 0

Value (% RH + Value)

Freeze

Manual Control B007 Off/On Off

Manual Position -1000 – 1000 0

Value (Temp + Value)

Digital Inputs

Power Loss

Manual DI 1 Off/On Off

Manual Position Closed/Open Closed

D1 Status

Filter Switch

Manual DI 2 Off/On Off

Manual Position Closed/Open Closed

D2 Status

High Pressure Switch

Manual DI 3 Off/On Off

Manual Position Closed/Open Closed

D3 Status

Low Pressure Switch

Manual DI 4 Off/On Off

Manual Position Closed/Open Closed

On to manually change temperature seen by controller

Degrees of change in sensor for manual control

Current temperature plus the value in manual position

On to manually change temperature seen by controller

Degrees of change in sensor for manual control

Current %RH plus the value in manual position

On to manually change temperature seen by controller

Degrees of change in sensor for manual control

Current temperature plus the value in manual position

"On" to allow artiﬁcial manipulation power loss input

Change to "Open" to artiﬁcally create power loss input

Current status of power loss input (closed means no input)

"On" to allow artiﬁcial manipulation ﬁlter switch input

Change to "Open" to artiﬁcally create ﬁlter switch input

Current status of ﬁlter switch input (closed means no input)

"On" to allow artiﬁcial manipulation of high pressure switch input

Change to "Closed" to artiﬁcally create high pressure input

Current status of high pressure input (open means no input)

"On" to allow artiﬁcial manipulation of low pressure switch input

Change to "Closed" to artiﬁcally create low pressure input

Manual 2100-643C Page 52 of 59

Screen Menu Item Range Default Value Description

D4 Status

Current status of low pressure input (open means no input)

Blower Status

Manual DI 5 Off/On Off

Manual Position Closed/Open Closed

D5 Status

"On" to allow artiﬁcial manipulation of blower status input

Change to "Closed" to artiﬁcally create blower status input

Current status of blower status input (open means no input)

Damper Switch

Manual Status DI 6 Off/On Off

Manual Position Closed/Open Closed

D3 Status

"On" to allow artiﬁcial manipulation of damper switch status input

Change to "Closed" to artiﬁcially create damper switch status input

Current status of damper switch status input (open means no input)

Relay Outputs

Cooling Stg 1

Manual Relay 2 Off/On Off

Manual Position Off/On Off

Relay 2 Status Off/On Off

"On" to allow artiﬁcial manipulation of cooling stage 1 relay action

Change to "On" to artiﬁcially force cooling stage 1 relay

Current status of cooling stage 1 relay (off means no relay action)

Cooling Stg 2

Manual Relay 3 Off/On Off

Manual Position Off/On Off

Relay 3 Status Off/On Off

"On" to allow artiﬁcial manipulation of cooling stage 2 relay action

Change to "On" to artiﬁcially force cooling stage 2 relay

Current status of cooling stage 2 relay (off means no relay action)

Heating

Manual Relay 6 Off/On Off

Manual Position Off/On Off

Relay 6 Status Off/On Off

"On" to allow artiﬁcial manipulation of heating relay action

Change to "On" to artiﬁcially force heating relay

Current status of heating relay (off means no relay action)

HVAC 2 Fail Alarm

Manual Relay 4 Off/On Off

Manual Position Off/On Off

Relay 4 Status Off/On Off

Blower

Manual Relay 7 Off/On Off

Manual Position Off/On Off

"On" to allow artiﬁcial manipulation of blower relay action

Change to "On" to artiﬁcially force blower relay

Manual 2100-643C Page 53 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Relay 7 Status Off/On Off

Analog Outputs

Analog Output 1

Blower Motor

Mode Hand/Auto Auto

Manual Value 0.0 – 10.0vdc 0vdc

Output 0.0 – 10.0vdc

Analog Output 2

Damper

Mode Hand/Auto Auto

Manual Value 0.0 – 10.0vdc 0vdc

Output 0.0 – 10.0vdc

End of TECHNICIAN

FACTORY

Initialization

Passwords

Insert new passwords

User 2000

Technician (PW1) 1313

Factory (PW2) 9254

Conﬁguration

Temperature Units °F/°C °F

Pressure Units psi/bar psi

Force Clock Enable Yes/No Yes

Clock Mode 24h/12h 24 hour

Disable Buzzer Yes/No Yes

Startup Delay 0s – 9999s 1 second

Enable Unit

by digit input On/Off On

by supervisor On/Off Off

by pLAN network On/Off On

by schedule On/Off Off

Analog Input Fitering

Enable No/Yes No

Input 1 4s – 256ms 19 seconds

Input 2 4s – 256ms 19 seconds

Input 3 4s – 256ms 19 seconds

Input 4 4s – 256ms 19 seconds

Input 5 4s – 256ms 19 seconds

Factory Settings

Manual Control Reset

Enable Yes/No Yes

Current status of blower relay (off means no relay action)

Manual 2100-643C Page 54 of 59

Screen Menu Item Range Default Value Description

Time 0m – 500m 60m

Local Setpoint Reset 0m – 180m 60m

PW/Return Delay 0s – 9999s 300s

I/O Conﬁguration

Analog Inputs

Supply Air Temp

Enable B001 On/Off On

Resolution

Normal/High Res.

Ohm x5, Ohm x1

NTC, PT1000,

0-1VDC,

0-10VDC,

Type

4-20mA, On/Off,

0-4VDC, NTC HT,

Normal Ohm x5

50T90, 10T170,

nu10,

SPKP00B7T0,

nu12, nu13

Minimum

Maximum

Offset

Value

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

0.0

100.0

0.0

Supply Air Temp

Input B001 ###

Out of Range Alarm

Power Delay 0s – 999s 5 Seconds

Run Delay 0s – 999s 5 Seconds

Pressure/

Units

Temperature/

Other

Outdoor Air Temp

Enable B002 On/Off On

Resolution

Normal/High Res.

Ohm x5, Ohm x1

NTC, PT1000,

0-1VDC,

0-10VDC,

Type

4-20mA, On/Off,

0-4VDC, NTC HT,

Normal Ohm x5

50T90, 10T170,

nu10,

SPKP00B7T0,

nu12, nu13

Minimum

-3276.8 –

3276.7

0.0

Manual 2100-643C Page 55 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Maximum

Offset

Value

Outdoor Air Temp

Input B002

Out of Range Alarm

Power Delay 0s – 999s 5 Seconds

Run Delay 0s – 999s 5 Seconds

Units

Return Air Temp

Enable B003 On/Off On

Resolution

Type

Minimum

Maximum

Offset

Value

Return Air Temp

Input B003

Out of Range Alarm

Power Delay 0s – 999s 5 Seconds

Run Delay 0s – 999s 5 Seconds

Units

Outdoor Humidity

Enable B005 On/Off On

Resolution

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

Pressure/

Temperature/

Other

Normal/High Res.

Ohm x5, Ohm x1

NTC, PT1000,

0-1VDC,

0-10VDC,

4-20mA, On/Off,

0-4VDC, NTC HT,

50T90, 10T170,

nu10,

SPKP00B7T0,

nu12, nu13

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

Pressure/

Temperature/

Other

Normal/High Res.

100.0

0.0

Temperature

Normal Ohm x5

0.0

100.0

0.0

Temperature

Manual 2100-643C Page 56 of 59

Screen Menu Item Range Default Value Description

Ohm x5, Ohm x1

NTC, PT1000,

0-1VDC,

0-10VDC,

Type

4-20mA, On/Off,

0-4VDC, NTC HT,

Normal 4-20mA

50T90, 10T170,

nu10,

SPKP00B7T0,

nu12, nu13

Minimum

Maximum

Offset

Value

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

0.0

100.0

0.0

Outdoor Humidity

Input B005

Out of Range Alarm

Power Delay 0s – 999s 5 Seconds

Run Delay 0s – 999s 5 Seconds

Pressure/

Units

Temperature/

Other

Freeze

Enable B007 On/Off On

Resolution

Normal/High Res.

Ohm x5, Ohm x1

NTC, PT1000,

0-1VDC,

0-10VDC,

Type

4-20mA, On/Off,

0-4VDC, NTC HT,

Normal 4-20mA

50T90, 10T170,

nu10,

SPKP00B7T0,

nu12, nu13

Minimum

Maximum

Offset

Value

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

-3276.8 –

3276.7

0.0

100.0

0.0

Outdoor Humidity

Input B007

Out of Range Alarm

Manual 2100-643C Page 57 of 59

WALL-MOUNT UNIT ARCHITECTURE (CONT.)

Screen Menu Item Range Default Value Description

Power Delay 0s – 999s 5 Seconds

Run Delay 0s – 535s 5 Seconds

Pressure/

Units

Digital Inputs

Power Loss Switch

Enable Channel 1 On/Off On

Action Closed/Open Closed

Delay 0s – 999s 0 Seconds

Status

Filter Switch

Enable Channel 2 On/Off On

Action Closed/Open Closed

Delay 0s – 999s 1 Second

Status

High Pressure Switch

Enable Channel 3 On/Off On

Action Closed/Open Open

Delay 0s – 999s 0 Seconds

Status

Low Pressure Switch

Enable Channel 4 On/Off On

Action Closed/Open Open

Delay 0s – 999s 0 Seconds

Status

Blower Status

Enable Channel 5 On/Off On

Action Closed/Open Closed

Delay 0s – 999s 0 Seconds

Status

Damper Switch

Enable Channel 6 On/Off On

Action Closed/Open Closed

Delay 0s – 999s 0 Seconds

Status

Relay Outputs

Cooling Stage 1

Enable No/Yes Yes

Channel 2

Direction N.O./N.C. N.O.

Status Off

Temperature/

Other

Pressure

Manual 2100-643C Page 58 of 59

Screen Menu Item Range Default Value Description

Cooling Stage 2

Enable No/Yes Yes

Channel 3

Direction N.O./N.C. N.O.

Status Off

Heating

Enable No/Yes Yes

Channel 4

Direction N.O./N.C. N.O.

Status Off

Blower

Enable No/Yes Yes

Channel 7

Direction N.O./N.C. N.O.

Status Off

Analog Outputs

Blower Motor

Enable Yes/No Yes

Channel 1/0 1

Action Direct/Reverse Direct

Minimum 0 – 10v 0v

Maximum 0 – 10v 10v

Damper

Enable Yes/No Yes

Channel 2/0 2

Action Direct/Reverse Direct

Minimum 0 – 10v 2.7v

Maximum 0 – 10v 10v

Factory Settings

Damper Delay Test

Enable Yes/No Yes

Voltage 0 – 10v 2.5v

Time 0s – 999s 30 seconds

Blower Status Switch

Minimum Off 0s – 999s 45 seconds

Unit Controller

Serial Number

00000000000000

Wall-mount unit serial number

Model Number 60 X Wall-mount unit model number

End of FACTORY

Manual 2100-643C Page 59 of 59

Bard D28A2PA, D36A2PA, D35A2PA, D28A2PB, D36A2PB Installation And Service Instructions Manual

Specifications and Main Features

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