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W42AAPB

Bard W24AAPA, W30AAPA, W24AAPB, W24AAPC, W30AAPB Service Instructions Manual

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SERVICE INSTRUCTIONS
WALL-MOUNT AIR CONDITIONER
Part of the Bard Free Cooling Unit System
W18AAPA W24AAPA W24AAPB W24AAPC W30AAPA W30AAPB W30AAPC W36AAEA W36AAEB
W42AAEA W42AAEB W42AAEC W42AAPA W42AAPB W42AAPC W48AAEA W48AAEB W48AAEC
MULTI-TEC
Models:
W60AAEA W60AAEB W60AAEC W60AAEQ W60AAMA W60AAMB W60AAMC W60AAPA W60AAPB
W72ABEA W72ABEB W72ABEC W72ABEQ W72ABMA W72ABMB W72ABMC W72ABPA W72ABPB
®
W18LAPA W24LAPA W24LAPB W30LAPA W30LAPB W30LAPC W36LAPA W36LAPB W36LAPC
W60LAPA W60LAPB W60LAPC W60LAPQ W72LBPA W72LBPB W72LBPC W72LBPQ
W36AAEC W36AAMA W36AAMB W36AAMC W36AAPA W36AAPB W36AAPC
wall-mount air conditioners are used.
W48AAEQ W48AAMA W48AAMB W48AAMC W48AAPA W48AAPB W48AAPC W48AAPQ
Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com
W60AAPC W60AAPQ
W72ABPC W72ABPQ
W42LAPA W42LAPB W42LAPC W48LAPA W48LAPB W48LAPC W48LAPQ
Manual : 2100-665D Supersedes: 2100-665C Date: 3-5-18
Page 1 of 26
CONTENTS
General Information ...........................................3
Free Cooling Unit System .......................................3
Wall-Mount Air Conditioner Units ............................3
General ................................................................3
Shipping Damage ..................................................4
Additional Publications ..........................................4
Using the TEC-EYETM ...........................................6
TEC-EYE Hand-Held Diagnostic Tool .......................6
TEC-EYE Menu Structure ......................... 7
TEC-EYE Acronyms ................................. 7
Status Screen ......................................... 7
Quick Menu............................................ 8
Setpoints: Local Col and Heat/
Current Cool and Heat ....................... 8
Information ...................................... 8
Data (Alarm) Log ............................... 8
Menu Screens and Password Levels .......... 8
Additional Features ................................. 8
Model/Serial Number Retain Feature .. 8
Time/Date/Timezone Sync .................. 9
Executing a Run Test............................... 9
Run Test Approximate Timings ........... 9
Parameter Description ....................... 9
Identifying a Unit Address ....................... 9
Changing Freecooling Type ....................... 9
Alarms .................................................................10
Acknowledging/Clearing Alarms .................... 10
Clearing Alarms .................................... 10
Clearing Alarm Logs .............................. 11
Alarm Adjustment ....................................... 11
Mixed Air Alarm .................................... 11
Refrigerant Low Pressure ....................... 11
Refrigerant High Pressure ...................... 12
Economizer Damper .............................. 12
Freezestat ............................................ 12
Control Operation .............................................13
On/Off Control ............................................ 13
Fan Control ................................................ 13
Temperature Control .................................... 13
Zone Selection...................................... 13
Cooling Sequence – Economizer Available
.. 13 Cooling Sequence –
Economizer Not Available ...................... 13
Heating Sequence ................................. 14
Freecooling ................................................ 15
Economizer Disable ............................... 15
Economizer Enable ............................... 15
None ............................................. 15
Drybulb Only .................................. 15
Temperature and Humidity (Default) . 15
Enthalpy ........................................ 15
Economizer Modulation ......................... 15
Compressor ................................................ 16
Enable ................................................. 16
Delays and Run Time............................. 16
Electric Reheat Dehumidification ................. 16
Mechanical Dehumidification ....................... 16
General Refrigerant Information ...................18
General ..................................................... 18
Topping Off System Charge .......................... 18
Safety Practices .......................................... 18
R410A Refrigerant Charge ........................... 18
Componentry .....................................................20
High Pressure Switch .................................. 20
Three Phase Scroll Compressor
Start Up Information ................................... 20
Phase Monitor ............................................ 20
Condenser Fan Operation ............................. 20
Low Ambient Control ................................... 20
Compressor Control Module ......................... 20
Pressure Service Ports ................................. 21
Outdoor Fan Motor ...................................... 21
Maintenance and Troubleshooting ...............24
Standard Maintenance Procedures ............... 24
Removal of Fan Shroud ............................... 24
Troubleshooting Nidec SelecTech ECM Motors
.. 25
FIGURES AND TABLES
Figure 1 MULTI-TEC Wall-Mount Unit Model
Nomenclature ........................................3
Figure 2 TEC-EYE Display and Interface ................6
Figure 3 TEC-EYE Connection to Unit Control ........6
Figure 4 Quick Menu Icons ...................................7
Figure 5 Local Cool/Heat and
Current Cool/Heat Setpoints.....................8
Figure 6 Alarm Log Screen Breakdown ..................8
Figure 7 Executing Run Test .................................9
Figure 8 Alarm Screen Breakdown.......................10
Figure 9 Clearing Alarms ....................................10
Figure 10 Clearing Alarm Logs ..............................11
Figure 11 Adjusting Mixed Air Alarm Values ...........11
Figure 12 Adjusting Damper Alarm Values .............12
Figure 13 LC6000 Status Screen Showing
Control Values ......................................13
Manual 2100-665D Page 2 of 26
Figure 14 Wall-Mount Unit Cooling Staging ............13
Figure 15 Adjusting Cooling Differential Values ......14
Figure 16 Adjusting Heating Differential Values ......14
Figure 17 Wall-Mount Unit Heating Staging ...........14
Figure 18 Economizer A4 Screen ..........................15
Figure 19 Economizer A5 Screen ..........................15
Figure 20 Adjusting Damper Modulation Value .......16
Figure 21 Dehumidification Control .......................17
Figure 22 Wall-Mount Unit Control Board ..............17
Figure 23 Fan Blade Setting .................................21
Figure 24 Motor Connections ................................25
Figure 25 Motor Connections ................................26
Table 1 Wall-Mount Unit Status Messages ............7
Table 2 LC1000/TEC-EYE Passwords (Defaults) ....8
Table 3 Wall-Mount Unit Alarm Index .................10
Table 4 Cooling Pressures .................................19
Table 5A Optional Accessories – Right Hand .........22
Table 5B Optional Accessories – Left Hand ...........23
GENERAL INFORMATION
Free Cooling Unit System
The Bard Free Cooling Unit system is composed of MULTI-TEC wall-mounted air conditioners matched with an LC6000 supervisory controller or Bard th­Tune stand-alone controller. If only one wall-mounted air conditioner is being used, it can be matched with either the LC6000 supervisory controller or a th-Tune stand-alone controller. If more than one wall-mount unit is installed, the LC6000 controller must be matched with the air conditioning units. The wall mounts are specifically engineered for telecom/motor control center rooms.
NOTE: The LC6000 supervisory controller and MULTI-
TEC wall-mount units are designed specifically to work together. The controller cannot run other brands of systems, nor can other controllers run the MULTI-TEC wall-mount units. They are a complete system, and must be used together.
Wall-Mount Air Conditioner Units
The MULTI-TEC units operate 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. In the event that freecooling operation cannot satisfy the load requirements, mechanical cooling will be utilized to assist in cooling the shelter.
will supply 100% of
MULTI-TEC units are available with electric heat and dehumidification options.
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 on page 4 for information on codes and standards.
MULTI-TEC Wall-Mount Unit Model Nomenclature
W 36 A A P A 10 5 X X X X E
MODEL SERIES
CAPACITY
18 – 1½ Ton
24 – 2 Ton
30 – 2½ Ton
36 – 3 Ton
M – PLC Logic Board w/Mechanical Dehumidification 
Reference Supplemental Instructions
42 – 3½ Ton
48 – 4 Ton 60 – 5 Ton 72 – 6 Ton
A – Right Hand
L – Left Hand
P – PLC Logic Board
E – PLC Logic Board w/Electric Reheat
A – 230/208/60/1 B – 230/208/60/3 C – 460/60/3 D – 240/220/50/1
7960-801 for complete details.
REVISION
VOLTS & PHASE
E – 240/220/50/3 or 220/200/50/3 F – 415/380/50/3 Q – 575/60/3
FIGURE 1
KW
VENTILATION OPTIONS
B – Blank-off Plate 5 – Economizer
CONTROL MODULES
E – Low Ambient Control C – Low Ambient Control & Crank Case Heater
COIL OPTIONS
X – Standard 1 – Phenolic Coated Evaporator 2 – Phenolic Coated Condenser 3 – Phenolic Coated Evaporator and Condenser
SUPPLY AIR OUTLET
X – Front (Standard)
COLOR OPTIONS
X – Beige (Standard) 1 – White 4 – Buckeye Gray
FILTER OPTIONS
X – 1" Throwaway (Standard) W – 1" Washable P – 2" Pleated (MERV 8)
Manual 2100-665D Page 3 of 26
Sizing of systems for proposed installation should be based on heat loss and heat gain calculations 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 furnace. 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
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.
Manual 2100-665D Page 4 of 26
!
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.
!
CAUTION
Cut hazard.
Wear gloves to avoid contact with sharp edges.
Failure to do so could result in personal injury.
Manual 2100-665D Page 5 of 26
USING THE TEC-EYE
TEC-EYE (Bard P/N 8301-059) Display and Interface (Status Screen Shown)
TM
FIGURE 2
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
TEC-EYE Hand-Held Diagnostic Tool
The microprocessor control used in the MULTI-TEC wall-mount air conditioners allows for complete control and monitoring through the use of the provided TEC­EYE 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 two menu levels: Quick Menu and Main Menu. The menus permit the user to easily view, control and configure the unit.
The controller is completely programmed at the factory; the default setpoints and their ranges are easily viewed and adjusted from the TEC-EYE display. The program and operating parameters are permanently stored on FLASH-MEMORY in case of power failure. The controller is designed to manage temperature levels to a user-defined setpoint via control output signals to the wall mount air conditioning system.
The TEC-EYE connects to the wall-mount unit control board via an RJ11 modular phone connector as shown in Figure 3.
UP KEY
ENTER KEY
DOWN KEY
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
FIGURE 3
TEC-EYE Connection to Unit Control
Modular Phone Connector for
TEC-EYE Hand-Held Diagnostic Tool
When not being used, the TEC-EYE hand-held diagnostic tool should be stored inside or near the LC6000 controller. Do not let the TEC-EYE leave the shelter.
Manual 2100-665D Page 6 of 26
TEC-EYE Menu Structure
Quick Menu Data Log Unit Information Setpoints Main Menu System Configuration Advanced System Configuration I/O Configuration On/Off Alarm Logs Settings Logout
In addition to the menu structure above, there are also Status and Alarm screens.
TEC-EYE Acronyms
MAT – Mixed air temperature RAT – Return air temperature OAT – Outdoor air temperature OAH – Outdoor air humidity Blower – Indoor Blower Status Damper – Free cooling damper position status C1 – Compressor activate status H1 – Heater Stage 1 status H2 – Heater Stage 2 status ODP – Calculated outdoor dew point FC – Free cooling status RN – Component run time in minutes in last hour ST – Number of start requests in last hour
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 wall-mount unit address is displayed in the upper right corner on the Status screen (see Figure 2). The Status screen also shows the current date, time, return air temperature, mixed air temperature, outdoor air temperature, outdoor humidity and outdoor dewpoint conditions. Blower, damper and unit status are also displayed. See Table 1 for MULTI-TEC wall-mount unit status messages.
The Quick Menu is displayed in the bottom right corner of the status screen (see Figure 2). Data Log, Unit Information and Setpoints are available through the Quick Menu. Pressing the UP or DOWN keys while on the Status screen will change the Quick Menu icon displayed (see Figure 4). Press the ENTER key when the desired icon is displayed.
TABLE 1
Wall-Mount Unit Status Messages
Message Description
Stand Alone Orphan Mode Standby
th-TUNE Online th-TUNE Standby
LC Online LC Standby
Cont. Blower Continuous Blower Active
Off by th-TUNE Unit off by th-TUNE
Freecooling Freecooling Active
Optimized Cool Optimized Cooling Active
Cooling Cooling Active
Heating Heating Active
Mechanical Dehumidification or
Active Dehum
Passive Dehum
Self Test Self Test Running
Off by Alarm Unit Off by Alarm Condition
Off by BMS Unit Off by BMS
Off by LC Unit Off by LC Master
Off by Keypad Unit Off by Keypad
Emergency Vent. Emergency Vent Mode Active
Emergency Cool Emergency Cool Mode Active
Emergency Off Emergency Off Mode Active
Electric Reheat Dehumidification
Active
Economizer Disable/Enhanced
Latent Removal (if available)
FIGURE 4
Quick Menu Icons
Data Log Unit Information
Setpoints
NOTICE
It is important to check the software version
during installation to ensure that the latest
version has been installed. Current software
versions, change log and installation
instructions are available on the Bard website at
http://www.bardhvac.com/software-download/
Manual 2100-665D Page 7 of 26
Quick Menu
Setpoints
If at any time the unit(s) loses communication with the LC6000 controller, the unit(s) will go to stand alone mode. The setpoints are synced with the LC6000 when communication is established. The unit will save and control to these values until communication is re­established.
To change the cooling and heating setpoints:
1. From the Status screen, press UP or DOWN key until Quick Menu displays Setpoints icon. Press ENTER key.
2. Press ENTER key to scroll to the selected choice (see Figure 5).
3. Press UP or DOWN key on desired value until value displays correctly.
4. Press ENTER key to submit value and move to next parameter.
5. Press ESCAPE key until Main Menu screen is displayed.
FIGURE 5
Cooling and Heating Setpoints
Information
These screens show unit demand, wall-mount unit status, serial/model number, hours, run hours, averages and software version information.
Data (Alarm) Log
The alarm log screens show a log of each alarm (see Figure 6. There will be a log for when alarm occurred and if the alarm auto clears, it will show when the alarm cleared. See page 11 for instructions on clearing the alarm logs.
NOTE
Screenshots shown in this manual reflect default settings (when applicable).
FIGURE 6
Alarm Log Screen Breakdown
Alarm Log Number
Alarm Date/Time
Alarm Index Number
Alarm Description
Alarm Event Type (Start/Stop)
TABLE 2
LC1000/TEC-EYE Passwords (Defaults)
User 2000
Technician 1313
Engineer 9254
Use UP or DOWN keys and ENTER key to enter password
Menu Screens and Password Levels
A System Config: User (2000)
B Adv Sys Config: Technician (1313)
C I-O Config: Technician (1313)
D On/Off: User (2000)
E Alarm Logs: User (2000)
F Settings
Date/Time: Technician (1313)
Language: User (2000)
Network Config: Technician (1313)
Serial Ports: Technician (1313)
Initialization
Clear Logs: User (2000)
System Default: Engineer (9254)
Restart: User (2000)
Parameter Config: Engineer (9254)
Alarm Export: User (2000)
G Logout: Used to log out of the current password
level. Entering back into the menu requires password.
Additional Features
Model/Serial Number Retain Feature
Model numbers and serial numbers will be retained through most software updates. It still remains good practice to verify the software version, model numbers and serial numbers of any wall-mount unit after a software update, as some functionality of the MULTI­TEC wall-mount unit require a specific model number.
Manual 2100-665D Page 8 of 26
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