INSTALLATION INSTRUCTIONS & REPLACEMENT PARTS LIST MC4000 SERIES SOLID STATE DUAL UNIT LEAD/LAG CONTROLLER Bard Manufacturing Company, Inc. Bryan, Ohio 43506 Since 1914...Moving ahead, just as planned. Manual No.: Supersedes: File: Date: 2100-563 NEW Vol.
CONTENTS Getting Other Information and Publications 3 MC4000 General Information Shipping Damage .................................................. 4 General .................................................................. 4 Theory of Operation ............................................... 4 Controller Certifications ......................................... 4 Specifications/Features for Basic Controller MC4000 Basic Controller .......................................
Getting Other Information and Publications These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.
** 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.
SPECIFICATIONS/FEATURES FOR BASIC CONTROLLER MC4000 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.
BASIC MC4000 CONTROLLER INPUT/OUTPUT SPECIFICATIONS SPECIFICATIONS/FEATURES FOR ALARM BOARDS MC4000 CONTROLLER CONNECTIONS MC4000-A w/Optional Base Alarm Board (Inputs/Outputs) Located on Main Controller Board C – 24VAC common R – 24VAC hot G – fan (Form A, NO) Y1 – 1st-stage cool (Form A, NO) Y2 – 2nd-stage cool (Form A, NO) W – heat (Form A, NO) Unit #2 C – 24VAC common R – 24VAC hot G – fan (Form A, NO) Y1 – 1st-stage cool (Form A, NO) Y2 – 2nd-stage cool (Form A, NO) W – heat (Form A, NO) F1-F2 Fire
LOW VOLTAGE FIELD WIRING The MC4000 is powered from the air conditioners that it is controlling, 24 VAC (18-32V) low voltage only. Circuitry in the MC4000 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 MC4000 and the other air conditioner are unaffected and will continue to operate normally.
GENERAL PROGRAMMING OVERVIEW MC4000 CONTROLLER BUTTONS AND FUNCTION On/Off Button 1. 2. Press and release the On/Off button to turn On controller, 4-character display will illuminate and Lead unit LED will light. Press and release the On/Off button to turn Off controller. Controller will go dark and A/C units will stop. Comfort Button 1. 2. 3. 4. Press and release the Comfort button to change the Cooling Set Point to 72F and the Heating Set Point to 68F for a period of 1 hour.
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.
4th cooling set point is 2F (default setting, user 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 set point is the setting (SP) input into the controller. Factory default is 77F (25C).
6. 2-Stage Compressor Units with Newer ECONWMT Economizers (See Note A) 1st stage cooling set point 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 10seconds before going solid, at which time the lead unit Y1 cooling output turns on.
3rd cooling set point is 2F (default setting, user selectable 2-3F) warmer than Stage 2. On a call for 3rd Stage cooling the blower of the lag unit is turned 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 set point of the economizer control.
5. 2-Stage Compressor Units with Newer ECONWMT Economizers (See Note A) 1st stage cooling set point 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.
SPECIFICATIONS FOR OPTIONAL REMOTE COMMUNICATION BOARD CB4000 COMMUNICATION BOARD Note: If this communication board was not originally factory installed it can be field-installed at anytime. Bard part number is CB4000. Either the –A or –B alarm board is required for CB4000 to operate properly. It allows remote access via Ethernet, depending upon level of authority assigned, to all functions of the controller system the same as it one was in the building where the controller system is physically installed.
SYSTEM STATUS PAGE 1. 2. 3. 4. This page shows the overall HVAC status of: a. Active cooling or heating stages or dehumidification mode (requires humidity sensor) b. Active controller outputs (blower, cooling Stage 1 or 2, heating) to each air conditioner c. Which unit is the Lead unit d. Power loss or refrigerant lock-out for each air conditioner e.
CONTROLLER WIRING GENERATOR RUN FEATURE The MC4000 can be used for controlling two (2) air conditioners with or without economizers. It can also be configured for two (2) heat pumps without economizers. Units with economizers will connect differently than units without economizers; therefore, it is important to use the correct connection diagram. If desired, the MC4000 controller can be signaled from a standby generator system to lockout (disable operation) of the lag air conditioning system.
TABLE 1 HOOK-UP DIAGRAM SELECTION TABLE — REFERENCE FIGURE 1 SHOWN System Type Model Series A/C with 1-Stage Compressor WA / WL W**A / W**L A/C with 2-Stage WA*S / WL*S Compressor Heat Pump WH / W**H SH / S**H Newer Older EIFM Newer ECONWMT Older EIFM Economizer ECONWMT MC4000-A or MC4000-B Economizer No Economizer — No with CB4000 Economizer — No with Communication with CB4000 Economizer Communication Communication Communication Board – No Economizer Communication Board Board Board Board 1 3 5 7
FIGURE 2 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS – NO ECONOMIZERS Manual 2100-563 Page 18 of 40
FIGURE 3 CONTROLLER CONNECTIONS 1-STAGE (WA/WL, W**A/W**L SERIES) AIR CONDITIONERS – NO ECONOMIZER WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual Page 2100-563 19 of 40
FIGURE 4 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS – NO ECONOMIZERS WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual 2100-563 Page 20 of 40
FIGURE 5 CONTROLLER CONNECTIONS 1-STAGE (WA/WL, W**A/W**L SERIES) AIR CONDITIONERS WITH OLDER STYLE EIFM ECONOMIZERS Manual Page 2100-563 21 of 40
FIGURE 6 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS WITH OLDER STYLE EIFM ECONOMIZERS Manual 2100-563 Page 22 of 40
FIGURE 7 CONTROLLER CONNECTIONS 1-STAGE (WA/WL, W**A/W**L SERIES) AIR CONDITIONERS WITH OLDER STYLE EIFM ECONOMIZERS AND WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual Page 2100-563 23 of 40
FIGURE 8 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS WITH OLDER STYLE EIFM ECONOMIZERS AND WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual 2100-563 Page 24 of 40
FIGURE 9 CONTROLLER CONNECTIONS 1-STAGE (WA/WL, W**A/W**L SERIES) AIR CONDITIONERS WITH (ECONWMT) ECONOMIZERS Manual Page 2100-563 25 of 40
FIGURE 10 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS WITH (ECONWMT) ECONOMIZERS Manual 2100-563 Page 26 of 40
FIGURE 11 CONTROLLER CONNECTIONS 1-STAGE (WA/WL, W**A/W**L SERIES) AIR CONDITIONERS WITH (ECONWMT) ECONOMIZERS AND WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual Page 2100-563 27 of 40
FIGURE 12 CONTROLLER CONNECTIONS 2-STAGE (WA*S/WL*S SERIES) AIR CONDITIONERS WITH (ECONWMT) ECONOMIZERS AND WITH ALARM BOARD & CB4000 COMMUNICATION BOARD Manual 2100-563 Page 28 of 40
FIGURE 13 CONTROLLER CONNECTIONS HEAT PUMPS – NO ECONOMIZER Manual Page 2100-563 29 of 40
FIGURE 14 CONTROLLER CONNECTIONS HEAT PUMPS – NO ECONOMIZER WITH OPTIONAL ALARM BOARD & CB4000 COMMUNICATION BOARD Manual 2100-563 Page 30 of 40
ALARM WIRING 2ND STAGE COOLING ALARM Alarm relays can be wired for NO (close on alarm) or NC (open on alarm) strategy. This alarm output is available for use if desired. It is important to note that in some installations, due to A/C system sizing and internal heat load, that the secondary (lag) air conditioning unit may be called upon to assist the lead air conditioner some of the time.
FIGURE 15 ALARM BOARD CONNECTIONS FOR NORMALLY CLOSED "NC" OPEN-ON-ALARM STRATEGY Note 1: 2nd Stage, Econ 1, Econ 2, High Temp 2 and Controller alarms are only on -B alarm board. All other alarms are on both -A and -B alarm boards. IMPORTANT! LED display board is shipped loose to protect it from possible damage during installation of the wiring to main controller board and/or the alarm board. It is polarity sensitive and is keyed so it can only be installed in correct position.
FIGURE 16 ALARM BOARD CONNECTIONS FOR NORMALLY OPEN "NO" CLOSE-ON-ALARM STRATEGY Note 1: 2nd Stage, Econ 1, Econ 2, High Temp 2 and Controller alarms are only on -B alarm board. All other alarms are on both -A and -B alarm boards. IMPORTANT! LED display board is shipped loose to protect it from possible damage during installation of the wiring to main controller board and/or the alarm board. It is polarity sensitive and is keyed so it can only be installed in correct position.
PROGRAMMING INSTRUCTIONS To swap lead and lag unit positions, press the ADVANCE button. To enter the Program mode, press the PROGRAM button and release it when the message PROG appears on the display. When in Program mode, the DOWN and UP arrows are used to scroll through the programming steps. A FLASHING display means that the function or choice is “SET”, and the display will alternate between the step function and setting.
MC4000 Solid State Dual Unit Lead Lag Controller CLIMATE CONTROL SOLUTIONS 1st Stage 2nd Stage 1st Stage 2nd Stage 3rd Stage 3rd Stage Alarms Power Loss Sys. 2 Refrig. Alarm Sys. 1 Refrig. Alarm Sys. 2 Fire/Smoke Alarm Low Temp. Alarm High Temp. Alarm 1 Lead Unit AB3000-A Alarm Board Functions AB3000-B Alarm Board Functions Power Loss Sys. 1 4th Stage 4th Stage High Temp.
FIGURE 17 PARTS LIST DESCRIPTION DIAGRAM 1 8 10 11 2 6 3 4 5 12 MIS-2954 7 Manual 2100-563 Page 36 of 40 9
Parts List D w g. N o. MC4000 MC4000-A MC4000-AC MC4000-B MC4000-BC AB3000-A AB3000-B CB4000 Part No.
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