Bard MC4002, MC4002-A, MC4002-AC, MC4002-B, MC4002-BC Installation Instructions & Replacement Parts List

...
INSTALLATION INSTRUCTIONS
&
REPLACEMENT PARTS LIST
MC4002 SERIES SOLID STATE
DUAL UNIT LEAD/LAG CONTROLLER
Bard Manufacturing Company, Inc. Bryan, Ohio 43506
Manual : 2100-614I Supersedes: 2100-614H Date: 7-13-18
Page 1 of 43
CONTENTS
Getting Other Information and Publications 3 MC4002 General Information
Shipping Damage ............................................... 4
General ............................................................. 4
Theory of Operation ............................................ 4
Controller Certifications ....................................... 4
Specifications/Features for Basic Controller
MC4002 Basic Controller .................................... 5
Mounting the Controller
Installation Instructions ...................................... 5
Temperature Sensors
Two Optional Sensor Inputs ................................. 5
Temperature Sensor Logic
Using Multiple Sensors ....................................... 5
Controller Input/Output Specifications
MC4002 Controller Connections .......................... 6
Specifications/Features for Alarm Boards
MC4002-A with Optional Base Alarm ................... 6
MC4002-B with Enhanced Version Alarm .............. 6
Low Voltage Field Wiring
Circuitry in the MC4002 ..................................... 7
Controller Grounding
Earth ground ...................................................... 7
Controller Power-Up
Time Delay on Power-Up ...................................... 7
Fire Suppression Circuit
Disabling the MC4002 ........................................ 7
Staging Delay Periods
Stages 1 - 4 ....................................................... 7
Blower Operation
Various Blower Options ........................................ 7
Advance (Swap) Lead/Lag Unit Feature
Manual Switching of Units .................................. 7
Accelerate Timer Feature
Testing the Timer Function .................................. 7
General Programming Overview
Buttons & Function ............................................. 8
Humidity Control Option
Adding Optional Humidity Control ........................ 9
Cooling Operating Sequences
for Alternating Lead/Lag/Lead/Lag Config .............. 9
Cooling Operating Sequences
for Non-Alt Lead/Lead/Lag/Lag Config ................. 11
Heating Sequence of Operation ............................. 13
Specifications Opt. Remote Comm. Board .............. 14
CB5000 Communications Board ........................ 14
Controller Wiring
Refer to Connection Diagram ............................. 18
Security (Locking) Feature
Locking and Unlocking the MC4002 .................. 18
Generator Run Feature
Standby Generator Disable Operation.................. 18
Backup DC Power Connection
Input Connections Available .............................. 18
Alarm Wiring ....................................................... 37
2nd Stage Cooling Alarm ...................................... 37
Refrigerant Pressure Alarms .................................. 37
Emergency Ventilation Sequence ........................... 37
Programming Instructions ..................................... 40
Figures
Figure 1 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C w/No Economizers ...........19
Figure 2 Controller Connections 1-Stage (W**AA/ W**LA
Series) A/C w/No Economizers ....................20
Figure 3 Controller Connections 2-Stage (WA*S/WL*S
Series) A/C - No Economizers .....................21
Figure 4 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C - No Econo with Alarm Board
& CB5000 Comm. Board ...........................22
Figure 5 Controller Connections 1-Stage (W**AA/ W**LA
Series) A/C - No Econo with Alarm Board &
CB5000 Comm. Board ..............................23
Figure 6 Controller Connections 2-Stage (WA*S/WL*S
Series) A/C - No Econo with Alarm Board &
CB5000 Comm. Board ..............................24
Figure 7 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C-Older EIFM Econo ...........25
Figure 8 Controller Connections 2-Stage (WA*S/WL*S ..
Series) A/C-Older Style EIFM Econo ............26
Figure 9 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C w/Older Style EIFM Econo &
w/Alarm Board/CB5000 Comm. Board .........27
Figure 10 Controller Connections 2-Stage (WA*S/WL*S ..
Series) A/C w/Older Style EIFM Econo &
w/Alarm Board/CB5000 Comm. Board ........28
Figure 11 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C w/ECONWMT Econo ..........29
Figure 12 Controller Connections 1-Stage (W**AA/ W**LA
Series) A/C w/WECOP Econo .......................30
Figure 13 Controller Connections 2-Stage (WA*S/WL*S
Series) A/C w/ECONWMT Econo ..................31
Figure 14 Controller Connections 1-Stage (WA/WL, W**A/
W**L Series) A/C w/ECONWMT Econo &
w/Alarm Board/CB5000 Comm. Board .........32
Figure 15 Controller Connections 1-Stage (W**AA/ W**LA
Series) A/C w/WECOP Econo & w/Alarm Board/
CB5000 Comm. Board ..............................33
Figure 16 Controller Connections 2-Stage (WA*S/WL*S
Series) A/C w/ECONWMT Econo & w/Alarm
Board/CB5000 Comm. Board .....................34
Figure 17 Controller Connections Heat Pumps -
No Economizers ........................................35
Figure 18 Controller Connections Heat Pumps -
No Economizers w/Opt. Alarm Board &
CB5000 Communication Board ..................36
— — — Alarm LED Display Board ........................... 37
Figure 19 Alarm Board Connections for Normally Closed
"NC" Open-On-Alarm Strategy .....................38
Figure 20 Alarm Board Connections for Normally Open
"NO" Close-On-Alarm Strategy ....................39
— — — MC Series Label ........................................ 41
Figure 21 Parts List Description Diagram ...................42
Tables
Table 1 Hook-Up Diagram Selection .......................19
— — — Parts List .................................................43
Manual 2100-614I Page 2 of 43
Getting Other Information and Publications
These publications can help when installing the air conditioner or heat pump. 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.
Standard for the Installation ........ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air Heating .....ANSI/NFPA 90B
and Air Conditioning Systems
For more information, contact these publishers:
ACCA Air Conditioning Contractors of America
1712 New Hampshire Avenue, NW Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721
ANSI American National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286
ASHRAE American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478
BARD Bard Manufacturing Company, Inc.
1914 Randolph Drive Bryan, OH 43506 Telephone: (419) 636-1194 Fax: (419) 636-2640
Manual 2100-614I Page 3 of 43
** IMPORTANT **
The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. Please read entire manual before proceeding.
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.
GENERAL
These instructions explain the operation, installation and troubleshooting of the MC4002 controller.
All internal wiring is complete. Only attach low voltage field wiring to designated terminal strips.
The MC4002 is for use with units with or without economizers, can be configured for use with heat pumps, and has a dehumidification control feature if an optional humidity controller is connected. Dehumidification control cannot be used with heat pump.
Each unit should be sized to handle the total load of the structure if 100% redundancy is required.
It is recommended that a 5-minute compressor time delay relay be installed in each unit if not so equipped.
The MC4002 controller can be configured for alternative (lead/lag/lead/lag) sequence, which is default setting. It can be changed to non-alternating (lead/lead/lag/lag) sequence as required for special applications or user preference.
The MC4002 can be equipped with one of two alarm boards, and these can be factory-installed or installed at any time in the field if so desired.
Should the base controller alone be initially installed, it is easily upgradeable by simple snap-in, plug-in field installation of either one of the alarm boards, requiring only the connection of the building alarm circuitry to the alarm boards. Form C dry contact alarm relays are used, offering both NO and NC switching to meet the user’s specific alarm protocol, providing complete flexibility to meet any user's requirements. All alarm actuations are individually indicated on the controller front panel.
There is an Ethernet-based remote communication option that can be either factory or field installed. See section on Communication Module.
CONTROLLER CERTIFICATIONS
The MC4002 main controller board, optional alarm boards, optional communication module, and remote sensors have undergone extensive testing for immunity and emissions. This system is FCC-compliant, in accordance with CE requirements, and meets the following standards:
MC4002 Series
Master Controller
The MC4002 controller is suitable for both 50 and 60 HZ operation, and is fully configurable such that it can be used in virtually any installation. See Controller Programmable Features and Default Settings.
THEORY OF OPERATION
The controller is used to control two wall mount air conditioners from one control system. It provides total redundancy for the structure and equal wear on both units. It can be used with units with or without economizers and it is recommended that both units be equipped alike.
CONFORMS TO UL STD 916 CERTIFIED TO CSA STD C22.2 NO. 205
Manual 2100-614I Page 4 of 43
This device complies with FCC Rule Part 15, Subpart B, Class A. Operation is subject to the following two conditions:
1. This device may not cause harmful interference
2. This device must accept any interference received, including that which may cause undesired operation.
This device complies with CE Standards EN55011/ EN50081 and EN55024 for ISM Equipment, Class A.
This ISM device also complies with Canadian ICES –
001.
Bard Manufacturing Company, Inc.
Bryan, OH 43506
SPECIFICATIONS/FEATURES FOR BASIC CONTROLLER
MC4002 Basic Controller
•Input power: 18-32 VAC, 60/50Hz, power is supplied from A/C #1 and/or A/C #2
•Isolation circuitry: no line or low voltage phasing required
•Backup power: connection for -24 VDC or -48 VDC (-20 to -56V) maintains microprocessor operation, front panel indication & alarm relay operation during commercial power outages.
•Digital display: 4-character LCD
•Temperature display: F or C
•HVAC outputs: Form A (NO) relays (1A @ 24 VAC)
•Cooling control stages: 2 for each A/C unit (4 total) when configured for economizers 1 for each A/C unit (2 total) when configured for no economizers
•Heating Control stages:
1 for each A/C unit, 2 for each heat pump if so configured
•Dehumidification circuit: requires optional humidity
controller as input signal
•Operating temperature range: 0 to 120F (-18 to 49C)
•Storage temperature range: -20 to 140F (-29 to 60C)
•Temperature accuracy: +/- 1F from 60-85F (16-30C)
+/- 1% outside 60-85F
•Lead/lag changeover time: 0 to 30 days
•Timing accuracy: +/- 1%
•Inter-stage time delay: 10 seconds between stages
•Inter-stage differential:
Stage 1 to 2 - Range 2-6F, default is 4 Stage 2 to 3 - Range 2-3F, default is 2 Stage 3 to 4 - Range 2-3F, default is 2
•On-Off differential: 2F (1C) is standard, 4F (3C) when
“excessive cycling” mode is enabled
•Cooling setpoint range: 65 to 90F (18.3 to 32.2C)
•Comfort setting-Cooling 72F (22C), Heating 68F(20C), for
1 hour
•Dead band (difference between cooling and heating
setpoints): 2F to 40F (1.1C to 22.2C)
•Fire/smoke interface: standard NC circuit jumper, remove
for connection to building system control, shuts down outputs to both A/C units immediately
•Memory: EEPROM for setpoint and changeable parameters
(maintains settings on power loss)
•Space temperature sensors: One (1) local is standard, will
accept up to twp (2) optional 35' remote sensors, Bard part number 8612-023A. When multiple sensors are used, temperatures are averaged
•Controller Enclosure: 20-gauge pre-painted steel, 9.25"W
x 13.50"H x 3.00"D, hinged cover, thirteen (13) .875" diameter electrical knockouts
•LEDs for basic controller: Lead unit, Cooling stages 1
through 4, Heating Stages 1 – 4, Dehumidification operation
•Six (6) Push-button controls: On/Off switch-Change lead
unit-Increase and Decrease setpoints-Program/Save-Comfort.
MOUNTING THE CONTROLLER
Included in the controller carton is the controller and installation instructions.
The controller should be installed on a vertical wall approximately 4 feet above the floor-away from drafts and outside doors or windows. Four (4) mounting holes are provided for mounting to the wall and 7/8" holes for conduit connections are provided in both the base, sides and top of the controller.
TEMPERATURE SENSORS
The standard (local) temperature sensor has 12" leads and comes installed from the factory.
A secondary sensor is located internally on the main controller board and serves as a reference and back-up sensor to the local sensor. If the difference between the two sensors is less than the differential setpoint, the local sensor will be used as the controller's temperature point of reference. The differential is adjustable from 12-20°F. 12°F is the default setting. If the difference between the two sensors is greater than the differential set-point, then the controller will check to determine if the on-board sensor is reading a temperature that is between the SP (set-point), plus the differential and the SP minus the DB (dead-band) minus the differential. If it is, the on-board sensor will become the valid sensor reading and the controller will ignore the local sensor reading. If not, then the controller, will still use the local sensor reading. This is to add additional levels of operational capability in the rare event the local sensor fails. If the controller is operating in this mode, it is indicated by the lower left decimal point flashing in the display. If this feature is not desired, set the differential set-point to OFF. This disables the on-board sensor. This may be necessary if the controller is located in one room and the local sensor has been relocated to a different room. Note: For
purposes of testing when the local sensor is manually driven higher or lower by applying warm or cool water to the probe the on-board sensor is inhibited for the first 30-minutes following power up, or when power is cycled off and back on.
The controller is designed to accept 1 or 2 additional sensors and those have 35-foot leads. The Bard part number for the optional sensor with 35-foot leads is 8612-023A. These can be installed as required in the structure to address hot spots, barriers to airflow, etc. If a remote sensor(s) is used, the on­board sensor is disabled. The local sensor remains active.
It is recommended that the sensor lead wires be installed in conduit for protective purposes.
NOTE: All sensors are polarity sensitive. The copper lead must connect to terminal CU, and the silver lead to AG. Sensors are solid state, not RTD. Use only sensors supplied by Bard. Sensor leads can be extended up to 200 feet. Use 18-gauge twisted pair with soldered connections.
TEMPERATURE SENSOR LOGIC
The standard local (LSEn) sensor monitors the temperature at the controller location. If this is the only sensor connected, it will control the temperature read-out, the space (building) temperature, and also be used for Low and High Temperature alarm functions.
If one or more REMOTE sensors are installed and connected (Rem 1 or Rem 2), the temperature read-out will display
and
Manual 2100-614I Page 5 of 43
the building will be controlled to an average of all connected sensors. If there is more than 10F difference from the highest to the lowest connected sensor, the actual control will be governed by the hottest sensor for cooling and the coldest sensor for heating.
If alarm boards are utilized, the highest reading of any connected sensor will be used for high temperature alarm and the lowest reading sensor will be used for low temperature alarm. The on-board sensor is ignored if two (2) or more sensors are connected to the Local, Rem 1 or Rem 2 sensor inputs.
BASIC MC4002 CONTROLLER INPUT/OUTPUT SPECIFICATIONS
MC4002 CONTROLLER CONNECTIONS
Located on Main Controller Board
Unit #1 C – 24VAC common
R – 24VAC hot G – fan (Form A, NO) Y1 – 1 Y2 – 2 W – heat (Form A, NO) Unit #2 C – 24VAC common R – 24VAC hot G – fan (Form A, NO) Y1 – 1 Y2 – 2 W – heat (Form A, NO) F1-F2 Fire/smoke interface Shipped with jumper installed (a) 48Vdc Back-up power input
-24Vdc or –48Vdc
-20V to –56V range
Local Main sensor, 12-inch leads CU – copper, AG – silver Polarity sensitive Rem 1 Optional remote indoor sensor CU – copper, AG – silver Polarity sensitive Rem 2 Optional remote indoor sensor CU – copper, AG – silver Polarity sensitive Gen Generator interface G1-G2 Shipped with jumper installed (a) H1-H2 Humidity controller input Requires optional controller Field installed
(a) These connections require either jumper or Normally Closed (NC) relay contact at the Fire/Smoke and Generator interface for Controller to function.
Note: All alarm and output relays are dry contacts rated 1A @ 24 VAC.
st
-stage cool (Form A, NO)
nd
-stage cool (Form A, NO)
st
-stage cool (Form A, NO)
nd
-stage cool (Form A, NO)
NOTE:
Sensors are
solid state,
not RTD.
Use Bard
sensors only.
Note: All alarm relay outputs have 10-second delay before issuing to protect against nuisance alarm signals.
SPECIFICATIONS/FEATURES FOR ALARM BOARDS
MC4002-A w/Optional Base Alarm Board (Inputs/Outputs)
NOTE: If this alarm board was not originally factory installed, it can be field-installed at anytime. Bard part number is AB3000-A.
Inputs
Lockout 1 2,3 – input from HVAC #1 Lockout 2 2, 3 – input from HVAC #2
Outputs
Smoke/Fire Form C (SPDT) Lockout 1 Form C (SPDT) Refrigerant alarm HVAC #1 Lockout 2 Form C (SPDT) Refrigerant alarm HVAC #2 Power Loss 1 Form C (SPDT) Power loss HVAC #1 Power Loss 2 Form C (SPDT) Power loss HVAC #2 Low Temp Form C (SPDT) Low temperature alarm High Temp 1 Form C (SPDT) High temperature alarm #1
MC4002-B w/Enhanced Version Alarm Board (Additional Outputs) plus MC4002-A Inputs/Outputs
NOTE: If this alarm board was not originally factory installed, it can be field-installed at anytime. Bard part number is AB3000-B.
High Temp 2 Form C (SPDT) High temperature alarm #2 Controller Form C (SPDT) Controller failure alarm – see note (a) Econ 1 E, F - Form A (NO) – see note (b) Econ 2 E, F - Form A (NO) – see note (b)
nd
Stage Form C (SPDT) – see note (c)
2 2
(a) Alarm will only activate if main board processor fails or if alarm board to main board cable is damaged.
(b) Make these connections to terminals E & F in HVAC 1 and 2 respectively if desired to have economizers open for emergency ventilation at High Temp Alarm #2 setpoint condition.
(c) For units with 2-stage compressors, 2nd stage cooling alarm activates on cooling Stage 3 initiation.
nd
-stage cooling alarm
Alarm relays can be wired for NO (close on alarm) or NC (open on alarm) strategy. Alarm relays can be used individually if there are enough available building alarm points, or can be arranged into smaller groups or even a single group so that all alarm capabilities can be utilized. When multiple alarms are grouped together and issued as a single alarm there will be no off-site indication of which specific problem may have occurred, only that one of the alarms in the group has been triggered. The individual alarm problem will be displayed on the LED display on face of the controller.
Manual 2100-614I Page 6 of 43
LOW VOLTAGE FIELD WIRING
The MC4002 is powered from the air conditioners that it is controlling, 24 VAC (18-32V) low voltage only.
Circuitry in the MC4002 isolates the power supplies of the two air conditioners so that no back feeds or phasing problems can occur. Additionally, if one air conditioner loses power, the MC4002 and the other air conditioner are unaffected and will continue to operate normally.
Connect the low voltage field wiring from each unit per the low voltage field wiring diagrams in Section on “Controller Wiring”. NOTE: Maximum of 18-gauge control wiring
should be used. Using heavier gauge wiring can create excessive stress on the control board as door is opened and closed. Create a wiring loop so the door can open and close without stressing terminal blocks.
CONTROLLER GROUNDING
A reliable earth ground must be connected in addition to any grounding from conduit. Grounding lugs are supplied for this purpose.
CONTROLLER POWER-UP
Whenever power is first applied to the controller, there is a twenty (20) second time-delay prior to any function (other than display) becoming active. This time-delay is in effect if the controller On/Off button is used when 24VAC from air conditioners is present, and also if controller is in “ON” position and 24VAC from air conditioners is removed and then restored.
FIRE SUPPRESSION CIRCUIT
To disable the MC4002 and shut down both air conditioners, terminals F1 and F2 may be used. The F1 and F2 terminals must be jumpered together for normal operation. A normally closed (nc) set of dry contacts may be connected across the terminals and the factory jumper removed for use with a field-installed fire suppression system. The contacts must open if a fire is detected. See appropriate connection diagram - Figures 1, 2 or 3 for this connection. Contacts should be rated for pilot duty operation at 2 amp 24VAC minimum. Shielded wire (22-gauge minimum) must be used, and the shield must be grounded to the controller enclosure.
IMPORTANT NOTE: Older Bard R-22 models employ an electronic blower control that has a 60-second blower off-delay. Current production R-410A models do not use a blower off-delay device and the remainder of this (paragraph) does not apply. In order to have immediate shutdown of the blower motor, in addition to disabling the run function of the air conditioners will require a simple wiring modification at the blower control located in the electrical control panel of the air conditioners being controlled by the lead/lag controller. To eliminate the 60-second blower off-delay, disconnect and isolate the wire that is factory-connected to the “R” terminal on the electronic blower control, and then connect a jumper from the “G” terminal on the blower control to
the “R” terminal on the blower control. The electronic blower control will now function as an on-off relay with no off-delay, and the blower motor will stop running immediately when the F1-F2 fire suppression circuit is activated (opened).
STAGING DELAY PERIODS
The following delays are built in for both cooling and heating:
Stage 1 – 0 seconds for blower (if not already on as
continuous) 10 seconds for cooling or heating output
Stage 2 – 10 seconds after Stage 1 for blower
10 additional seconds for cooling or heating output
Stage 3 – 10 seconds after Stage 2
Stage 4 – 10 seconds after Stage 3
Note: For cooling Stages 1 and 2, the stage LED will
blink for 10 seconds while the cooling output is delayed after that stage is called for. There is also a delay after the stage is satisfied, and after the LED stops blinking, the stage will turn off. There is a minimum 10-second delay between stages 2 & 3, and 3 & 4, but no delayed output when stage is turned on or off, and LED for those stages will not blink.
BLOWER OPERATION
The controller can be configured to have main HVAC blowers cycle on and off on demand; have all blowers run continuously; or have the lead unit blower run continuously with the lag unit blower cycling on demand. Default setting is the blower(s) start and stop on demand. There is also an option to have all blowers cycle on if one remote sensor is connected, and a temperature difference of more than 5F between any two sensors is observed. This helps to redistribute the heat load within the structure and should reduce compressor operating time.
When any of the stages are satisfied, the stage LED will blink for ten (10) seconds before the stage is actually turned off.
ADVANCE (SWAP) LEAD/LAG UNIT FEATURE
Pressing the Advance button for one (1) second will cause the lead and lag units to change positions. This may be useful during service and maintenance procedures.
ACCELERATE TIMER FEATURE
Pressing the UP arrow button for five (5) seconds will activate an accelerate (speed-up) mode, causing the normal changeover time increments of days to be reduced to seconds. Example: 7 days becomes 7 seconds. When “ACC” displays, release button. Whichever LED is on, indicating lead unit will blink over for each second until the controller switches. This is a check for the timer functionality.
Manual 2100-614I Page 7 of 43
GENERAL PROGRAMMING OVERVIEW
MC4002 CONTROLLER BUTTONS AND FUNCTION
On/Off Button
1. Press and release the On/Off button to turn On controller, 4-character display will illuminate and Lead unit LED will light.
2. Press and release the On/Off button to turn Off controller. Controller will go dark and A/C units will stop.
Comfort Button
1. Press and release the Comfort button to change the Cooling Setpoint to 72F and the Heating Setpoint to 68F for a period of 1 hour.
2. Setpoints will return to the programmed settings automatically after 1 hour.
3. Pressing the Comfort button during the 1 hour period will deactivate the Setpoint change.
4. The temperature display will flash the current temperature while in override mode.
Program Button
1. Press the Program button and release it when the message “Prog” appears on the display.
2. Refer to Programming Instructions and follow these commands to change from Default settings.
Advance/Change/Save Button
1. Press and release the Advance button to swap lead and lag unit positions.
2. When in Program mode the Down and Up buttons are used to scroll through the programming steps.
3. A flashing display means that the particular function of that programming step is “set”, and the display will alternate between the step
function and the setting.
4. To change the setting press the Change button and the display will stop flashing, allowing change to the setting.
5. Use Down or Up arrows to change setting as desired, and press the Save button and proceed as desired.
6. When done with programming changes press the Program button until display stops flashing and room
temperature is shown.
Up and Down Buttons
These buttons are used to change the settings in conjunction with the Advance/Change/Save button when in programming mode.
CONTROLLER PROGRAMMABLE FEATURES AND DEFAULT SETTINGS
Order/
Display
LSEn Temperature at local (main) sensor
cFAn Continuous blower operation None, Lead, Both None
LLCO Lead-Lag changeover time (Days) 1 - 30 days, or 0 for disabled 7
Cbd5 Unit 1 and 2 blowers automatically both run if delta T >5F between any 2 connected sensors Yes or No Yes
OFde 3-minute lead unit & 4-minute lag unit off-delay enabled Yes or No No
LoAL Low temperature alarm setpoint 28 to 65F (-2 to 18C) 45F (7.2C)
HAL1 High temperature alarm level #1 setpoint 70F to 120F (21 to 49C) 90F (32C)
HAL2 High temperature alarm level #2 setpoint 70F to 120F (21 to 49C) 95F (35C)
Locd Controller is locked and no changes can be made. Consult building authority.
Inter-Stage Differential
ISd2 From Stage 1 to Stage 2 2, 3, 4, 5 or 6F 4
ISd3 From Stage 2 to Stage 3 2 or 3F 2
ISd4 From Stage 3 to Stage 4 2 or 3F 2
On/Off Differential (Hysterisis)
CSon Turn "On" above SP for Stage 1 Cooling +1 or 2F 2
CSoF Turn "Off" below SP for Stage 1 Cooling -1, 2, 3 or 4F -2
HSoo All Heating Stages are equal -/+ on & off differential -1/+1 or -2/+2 -2/+2
CoPr
ob5d Differential between Local and On-Board Sensor 12 to 20, OFF 12
Description Range/Choice Default
SP Cooling setpoint temperature 65 to 90F (18 to 32C) 77F (25C)
db Deadband between cooling SP and heating setpoint 2 to 40F (1 to 24C) 17F (9.4C)
r1 Temperature at remote sensor 1 location, if connected
r2 Temperature at remote sensor 2 location, if connected
deg Controller system operates in F or C F or C F
Alternating Lead-Lag-Lead-Lag sequence or Non-Alternating Lead-Lead-Lag-Lag sequence —
Alt
Yes = Alternating
Heat pump logic enabled — only for 1-stage heat pumps and forces Lead-Lag sequence
HP
(overrides a Non-Alt setting)
crun Minimum 3-minute compressor runtime enabled Yes or No No
Stage 2, 3 and 4 Cooling automatically set same as Stage 1 decisions
1 or 2-stage compressor, if set to 1 the 2nd stage Cooling Alarm activates on Cooling Call 2, if set to 2 the 2nd stage Cooling Alarm activates on Cooling Call 3
Yes or No Yes
Yes or No No
If locked, display will show Locd if changes attempted
1 or 2 1
Unlocked
Manual 2100-614I Page 8 of 43
HUMIDITY CONTROL OPTION
Note: This function is not available if controller is configured for heat pump.
The standard air conditioning system can be adapted to perform dehumidification control by addition of a simple humidity controller that closes-on-rise, and is connected to terminals H1 and H2 on the main controller board. Recommended Bard Part #8403-038 (H600A 1014). Both HVAC units must be equipped with electric heat for this sequence to work properly. See appropriate connection diagram - Figures 1 - 12 for this connection:
1. Temperature control always has priority over dehumidification. If there is any stage of cooling demand active, the dehumidification sequence is locked out.
2. If all stages of cooling are satisfied, and relative humidity is above the setpoint of humidity controller:
a. The green “Dehumid. Operation” light will come on, and the lag unit compressor and blower will operate until the setpoint of humidity controller is satisfied (or cancelled by a call for cooling).
b. If the space temperature drops to 67F, the electric heater of the lead unit will cycle to help maintain building temperature. It will cycle off at 69F.
c. If space temperature drops to 64F, the Stage 2 Heating light will come on and the lag unit compressor operating for dehumidification mode will cycle off until the building temperature rises above 65F from 1st stage heat and building load. The green “Dehumid. Operation” light stays on during this sequence, and when Stage 2 Heating light is Off, the compressor is On. The electric heater in lag unit is locked out in dehumidification mode.
Lag unit outputs G, Y1 and Y2 are all switched on during dehumidification sequence. This is true for both alternating and non-alternating controller configurations.
CAUTION
Humidity controller setpoint should be in 50-60% relative humidity area: Setting controller to lower settings will result in excessive operating time and operating costs for the electric reheat, and in extreme cases could cause evaporator (indoor) coil freeze-up if there are periods of light internal equipment (heat) loading.
COOLING OPERATING SEQUENCES FOR ALTERNATING LEAD/LAG/LEAD/ LAG CONFIGURATION
1. 1-Stage Compressor Units No Economizer
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the compressor will start.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2 Stage cooling the blower of the lag unit is turned on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the compressor will start.
rd
and 4th stages are functional outputs but there is
3 nothing to be controlled.
2. 2-Stage Compressor Units No Economizer
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit compressor will start in compressor Stage 1 partial capacity operation.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for
nd
Stage cooling the blower of the lag unit is turned
2 on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the lag unit compressor will start in compressor Stage 1 partial capacity operation.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for
rd
Stage cooling the Stage 3 LED comes on solid (no
3 delay), and the lead unit compressor will switch to compressor Stage 2 full capacity operation.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the Stage 4 LED comes on solid (no delay), and the lag unit compressor will switch to compressor Stage 2 full capacity operation.
3. 1-Stage Compressor Units with Older EIFM Economizers (Enthalpy OD Sensor)
1st stage cooling setpoint is the setting (SP) input into the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If
nd
the
Manual 2100-614I Page 9 of 43
outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2
nd
Stage cooling the blower of the lag unit is turned on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
rd
Stage cooling the lead unit economizer will close and the compressor will operate.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the lag unit economizer will close and the compressor will operate.
4. 1-Stage Compressor Units with Newer ECONWMT or WECOP Economizers (See Note A)
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2
nd
Stage cooling the blower of the lag unit is turned on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
rd
Stage cooling the lead unit economizer will continue to
operate as long as outdoor conditions are acceptable, and the compressor will operate.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the lag unit economizer will continue to operate as long as outdoor conditions are acceptable, and the compressor will operate.
5. 2-Stage Compressor Units with Older EIFM Economizers
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2 Stage cooling the blower of the lag unit is turned on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3 Stage cooling the lead unit economizer will close and the compressor will operate on full capacity compressor Stage 2.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the lag unit economizer will close and the compressor will operate on full capacity compressor Stage 2.
6. 2-Stage Compressor Units with Newer ECONWMT or WECOP Economizers (See Note A)
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the
nd
rd
Manual 2100-614I Page 10 of 43
economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2
nd
Stage cooling the blower of the lag unit is turned on (if not already on – See Blower Operation), and the Stage 2 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
rd
Stage cooling the lead unit economizer will continue to operate as long as outdoor conditions are acceptable, and the compressor will operate on compressor Stage 1 partial capacity. If outdoor conditions are not acceptable for free cooling the lead unit compressor will automatically be operating on compressor Stage 1 partial capacity and will go to Stage 2 full capacity operation.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4
th
Stage cooling the lag unit economizer will continue to operate as long as outdoor conditions are acceptable, and the compressor will operate on compressor Stage 1 partial capacity. If outdoor conditions are not acceptable for free cooling the lag unit compressor will automatically be operating on compressor Stage 1 partial capacity and will go to Stage 2 full capacity operation.
COOLING OPERATING SEQUENCES FOR NON-ALTERNATING LEAD/LEAD/ LAG/LAG CONFIGURATION
Note: Heat pumps cannot be operated in Non­Alternating Lead/Lead/Lag/Lag sequence. Selecting Heat Pump = Yes will override a Non-Alternating selection and force system to Alternating Lead/Lag/ Lead/Lag sequence.
1. 2-Stage Compressor Units No Economizer
st
stage1st stage cooling setpoint is the setting (SP)
1 input into the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit compressor will start in compressor Stage 1 partial capacity operation.
2nd cooling setpoint is 4F (default setting, user selectable 2-6F) warmer than Stage 1, at which time the lead unit compressor will switch to compressor Stage 2 full capacity.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3 Stage cooling the blower of the lag unit will come on immediately (if not already on – See Blower Operation), and Stage 3 LED will blink for 10-seconds before going solid, and then the lag unit compressor will start in compressor Stage 1 partial capacity.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the Stage 4 LED comes on solid (no delay), and the lag unit compressor will switch to compressor Stage 2 full capacity operation.
2. 1-Stage Compressor Units with Older EIFM Economizers
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2 Stage cooling the lead unit Y2 cooling output turns on. The lead unit economizer will close and the compressor will operate. If the compressor is already running from
st
1
stage cooling call due to outdoor conditions being outside of free cooling range no action occurs at 2 stage setpoint.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for
rd
Stage cooling the blower of the lag unit is turned
3 on (if not already on – See Blower Operation), and the Stage 3 LED will blink for 10-seconds before going solid, and the lag unit economizer will operate if the outdoor temperature and humidity conditions are below the setpoint of the economizer control. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4th Stage cooling the lag unit economizer will close and the compressor will operate. If the compressor is already
rd
running from 3
stage cooling call due to outdoor conditions being outside of free cooling range no action occurs at 2
nd
stage setpoint.
rd
nd
nd
Manual 2100-614I Page 11 of 43
3. 1-Stage Compressor Units with Newer ECONWMT or WECOP Economizers (See Note A)
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for
nd
stage cooling the lead unit Y2 cooling output turns
2 on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will continue to operate, and the compressor will operate. If the compressor is already operating on 1 cooling range no action occurs at 2
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
st
stage cooling because outside free
nd
cooling setpoint.
rd
Stage cooling the blower of the lag unit will come on immediately (if not already on – See Blower Operation), and the Stage 3 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. The lag unit economizer will operate if the outdoor temperature and humidity conditions are below the setpoint of the economizer control. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate instead of the economizer.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for
th
Stage cooling the lag unit Y2 cooling output turns
4 on activating the lag unit compressor. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will continue to operate. If the compressor
rd
is already operating on 3 outside free cooling range no action occurs at 4
stage cooling because
th
cooling setpoint.
4. 2-Stage Compressor Units with Older EIFM Economizers
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will
operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for 2
nd
stage cooling the lead unit Y2 cooling output turns on, at which time the lead unit compressor will operate on compressor Stage 2 full capacity. If the compressor is already operating on Stage 1 partial capacity because outside free cooling range the compressor will switch to compressor Stage 2 full capacity.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
rd
Stage cooling the blower of the lag unit will come on immediately (if not already on – See Blower Operation), and the Stage 3 LED will blink for 10-seconds before going solid. The lag unit economizer will operate if the outdoor temperature and humidity conditions are below the setpoint of the economizer control. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4
th
Stage cooling the lag unit Y2 cooling output turns on, at which time the lag unit compressor will operate on compressor Stage 2 full capacity. If the compressor is already operating on Stage 1 partial capacity because outside free cooling range the compressor will switch to compressor Stage 2 full capacity.
5. 2-Stage Compressor Units with Newer ECONWMT or WECOP Economizers (See Note A)
st
stage cooling setpoint is the setting (SP) input into
1 the controller. Factory default is 77F (25C). On a call for cooling the blower of the lead unit will come on immediately (if not already on – See Blower Operation), and the Stage 1 LED will blink for 10-seconds before going solid, at which time the lead unit Y1 cooling output turns on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will operate instead of the compressor. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
nd
cooling setpoint is 4F (default setting, user
2 selectable 2-6F) warmer than Stage 1. On a call for
nd
stage cooling the lead unit Y2 cooling output turns
2 on. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lead unit economizer will continue to operate, and the compressor will operate on compressor Stage 1 partial capacity. If the compressor is already operating on Stage 1 partial capacity because outside free cooling
Manual 2100-614I Page 12 of 43
range the compressor will switch to compressor Stage 2 full capacity.
rd
cooling setpoint is 2F (default setting, user
3 selectable 2-3F) warmer than Stage 2. On a call for 3
rd
Stage cooling the blower of the lag unit will come on immediately (if not already on – See Blower Operation), and the Stage 3 LED will blink for 10-seconds before going solid, at which time the lag unit Y1 cooling output turns on. The lag unit economizer will operate if the outdoor temperature and humidity conditions are below the setpoint of the economizer control. If outdoor conditions are not acceptable for free cooling the compressor will automatically operate on compressor Stage 1 partial capacity instead of the economizer.
th
cooling setpoint is 2F (default setting, user
4 selectable 2-3F) warmer than Stage 3. On a call for 4
th
Stage cooling the lag unit Y2 cooling output turns on activating the compressor. If the outdoor temperature and humidity conditions are below the setpoint of the economizer control the lag unit economizer will continue to operate, and the compressor will operate on compressor Stage 2 full capacity. If the compressor is already operating on Stage 1 partial capacity because outside free cooling range the compressor will switch to compressor Stage 2 full capacity.
Note A: Economizers in ECONWMT or WECOP Series are available with either “T” temperature only outdoor sensor or “E” enthalpy (temperature and humidity) outdoor sensor. The “T” versions will have a fixed (but selectable) outdoor temperature decision whereas on the “E” versions the outdoor temperature decision will float based on outdoor humidity and the selected Enthalpy curve in the economizer control module.
HEATING SEQUENCE OF OPERATION
Note: All heating sequences for air conditioners with electric heat or heat pumps will automatically operate in Alternating Lead/Lag/Lead/Lag sequence even if controller is set to Non-Alternating for cooling with or without economizers.
1. Air Conditioners with Electric Heat
st
stage heating setpoint is the dead-band (db) below
1
st
stage cooling setpoint (the SP entered into the
the 1 program). The dead-band is adjustable from 2-40F, and factory default is 17F.
nd
stage heating setpoint will operate at same inter-
2 stage differential as set for cooling mode.
2. Heat Pumps with Electric Heat
When the MC4002 controller is configured for heat pump installations the 2 units 1 and 2 are redefined and used to control the reversing valves, and which are energized in heating mode.
st
stage heating setpoint is the dead-band (db) below
1
st
stage cooling setpoint (the SP entered into the
the 1 program). The dead-band is adjustable from 2-40F, and factory default is 17F.
st
-stage heating consists of lead unit blower coming
1 on (if not already on – See Blower Operation), and reversing valve being energized. The Stage 1 heating LED will blink for 10-seconds, at which time the compressor turns on.
nd
heating setpoint is 4F (default setting, user
2 selectable 2-6F) cooler than Stage 1. On a call for 2 Stage heating the blower of the lag unit is turned on (if not already on – See Blower Operation), the reversing valve is energized, and the Stage 2 LED will blink for 10-seconds before going solid, at which time the compressor will start.
rd
-stage heating will be the electric heater, if so
3 equipped, in the lead unit. Stage 3 heating LED comes on solid with no blinking.
th
-stage heating will be the electric heater, if so
4 equipped, in the lag unit. Stage 4 heating LED comes on solid with no blinking.
nd
-stage (Y2) outputs for both
nd
Manual 2100-614I Page 13 of 43
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