Bard W48A2PQ Installation And Service Instructions Manual Download

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AIR CONDITIONER MODELS

W48A2PQ W48L2PQ
W60A2PQ W60L2PQ
W72A2PQ W72L2PQ

CONTROLLER MODEL

LC5000-100

NOTE: BARD-LINK

™

LC5000-100 Controller is required for operation when

multiple W***2PQ units are used.

INSTALLATION AND

SERVICE INSTRUCTIONS

Bard Manufacturing Company, Inc.

Bryan, Ohio 43506

www.bardhvac.com

Manual :

2100-642

Supersedes:

NEW

Date: 9-15-15

FREE COOLING UNIT SYSTEM

WALL-MOUNTED PACKAGE

AIR CONDITIONER(S)

BARD-LINK™ PLC

LEAD/LAG CONTROLLER

Summary of Contents for W48A2PQ

Page 1: ...LC5000 100 Controller is required for operation when multiple W 2PQ units are used INSTALLATION AND SERVICE INSTRUCTIONS Bard Manufacturing Company Inc Bryan Ohio 43506 www bardhvac com Manual 2100 64...

Page 2: ...Mount Unit Supply Wiring 15 Preliminary Start Up 18 Bard LinkTM Controller Installation 19 System Start Up 31 SECTION 2 Service Instructions 35 General Refrigerant Information 36 Sequence of Operation...

Page 3: ...elief openings in the shelter Each of these units are fully charged with refrigerant and have auxilliary heat installed BARD LINKTM PLC CONTROLLER LC5000 100 controller and accessories included with c...

Page 4: ...r 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 e...

Page 5: ...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 wit...

Page 6: ...Manual 2100 642 Page 6 of 82...

Page 7: ...Manual 2100 642 Page 7 of 82 SECTION 1 INSTALLATION INSTRUCTIONS...

Page 8: ...5 wire 18 gauge shielded cable with drain for remote temperature and humidity sensor CAT 6 Ethernet cable of field determined length for remote communication if applicable Miscellaneous electrical sup...

Page 9: ...f 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 Recirculati...

Page 10: ...R HEATER ACCESS PANEL SIDE VIEW DRAIN DT K J C A I H D 2 13 7 Built In OPENING RETURN AIR OPENING SUPPLY AIR Brackets Mounting OPENING SUPPLY AIR Optional Entrances Electrical Side Wall BOTTOM INSTALL...

Page 11: ...page 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 inspe...

Page 12: ...LE MATERIALS A B C D E 30 1 2 10 1 2 6 1 4 1 1 4 29 3 4 32 12 5 1 2 2 RETURN AIR OPENING 29 1 Right Side View NOTES SUPPLY AIR RAIN FLASHING IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACE...

Page 13: ...ME 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 UNI...

Page 14: ...TO MATCH STUD SPACING FOR REST OF WALL A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS MIS 549 B ALL AROUND DUCT FIGURE 1 7 Common Wall Mounting Installations SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR...

Page 15: ...attention to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three 3 current carrying conductors are in a raceway Maximum size of the time delay fuse or circuit breaker for pr...

Page 16: ...ge tap is used FIGURE 1 8 Circuit Routing Label See Figure 1 9 to reference VAC landing points The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect To...

Page 17: ...ect 575V voltage 2 Confirm correct wires are connected For 575V the gray 575 and black common transformer wires must be used Shelter supply breaker in ON position Bard system breaker in OFF position 5...

Page 18: ...vation 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...

Page 19: ...CONTROLLER INSTALLATION FIGURE 1 11 Typical LC5000 Wiring PLC Board Smoke Alarm Jumper RJ11 Cable to Display Power Input 120V 230V 240V Transformer Ethernet Cable Connection Zone 1 2 3 Sensor Shielded...

Page 20: ...holes for conduit connections are provided in both the base sides and top of the controller Electrical shock hazard Disconnect VAC power supplies before servicing Failure to do so could result in ele...

Page 21: ...e remote indoor temperature humidity sensor is included with the controller This sensor must be installed for proper operation Use shielded cable to mount the temperature humidity sensor in a location...

Page 22: ...e purchased and installed in Zones 2 and 3 one per zone For information on remote indoor sensor configuration see section on additional sensors beginning on page 46 10 4 3 2 29 1 6 7 8 9 11 12 1314 15...

Page 23: ...00 PLC controller is shipped with smoke detector contacts There is a factory installed jumper across terminals 23 and 24 If there is no smoke detector no action is necessary If smoke detector alarm is...

Page 24: ...e controller in the manner shown in Figure 1 15 The communication wire should be 2 wire 18 gauge shielded cable with drain Any color can be used Be sure to match and symbols on controller terminal blo...

Page 25: ...filter at the intersection of the loop FIGURE 1 16 Communication Wiring Termination at the Controller 2 Connect one wire to terminal 27 negative the other wire to terminal 28 positive and the drain w...

Page 26: ...nal block Make sure to match and symbols on controller terminal blocks 2 Connect the wires matching the terminal designations of the controller terminals Leave the drain wire loose 3 Connect another c...

Page 27: ...ach EMI filter as shown FIGURE 1 18 Communication Wiring Termination at Additional Wall Mount Units 2 Connect the wires matching the terminal designations of the controller terminals Cap the loose dra...

Page 28: ...y grounding from conduit Grounding posts are included with the controller for this purpose install as shown in Figure 1 20 Failing to ground the controller box properly could result in damage to the e...

Page 29: ...mote Sensor Zone 2 11 GND Ground 12 B4 Indoor Remote Sensor Zone 3 13 GND Ground 14 B5 Remote Indoor Humidity Sensor 0 1 VDC Zone 3 15 GND Ground 16 VDC Power for B5 17 B6 Remote Indoor Humidity Senso...

Page 30: ...ED RED BLK RED YELLOW YELLOW BLUE BLK BLK WHITE BLACK BLACK BLUE YELLOW TB 8 TB 10 TB 12 TB 14 TB 17 TB 20 TB 21 TB 16 27 28 PLAN RX TX PLAN RX TX BLACK BLACK TB 27 JMP TB Wire Mark Description 1 115...

Page 31: ...Use the UP arrow key to change unit count to the number of units that will be connected to the LC controller see Figure 1 23 FIGURE 1 23 Total Units Displayed 3 Set Up and Configure Units Set up and c...

Page 32: ...the value of a modifiable field ALARM KEY MENU KEY ESCAPE KEY DOWN KEY UP KEY ENTER KEY 9 Reattach communication wire connection plug to wall unit control board that was removed in Step 1 After first...

Page 33: ...e wiring connections on the units showing as offline 4 Repeat Steps 1 3 to confirm unit online status and further diagnose connection issues if necessary 5 Run Test Units Using the TEC EYE a run test...

Page 34: ...all the installation steps have been completed and system verification and run test results were satisfactory the installation can now be considered complete The Bard LinkTM PLC lead lag controller ha...

Page 35: ...Manual 2100 642 Page 35 of 82 SECTION 2 SERVICE INSTRUCTIONS...

Page 36: ...a guideline 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 instruction...

Page 37: ...2 139 427 141 454 143 481 145 510 147 540 85 DB 72 WB Low Side High Side 134 323 136 345 138 367 140 391 142 416 144 442 146 470 148 498 150 528 152 559 W72 75 DB 62 WB Low Side High Side 116 329 117...

Page 38: ...mper Signal Modulates damper to achieve 55 F at supply air temperature sensor 2 24VAC from terminal N07 Blower Motor Start Relay If the outdoor conditions are conducive to free cooling but a 2nd stage...

Page 39: ...sed by the freezestat the compressor will deactivate for 5 minutes or until the sensor sees 55 F whichever comes first FIGURE 2 2 Wall Mount Unit Control Board Dirty Filter Switch High Pressure Alarm...

Page 40: ...power to hydrogen detector through terminals 3 and 4 The terminal block is fused internally see Componentry section 24VDC power to smoke detector through terminals 6 and 7 The terminal block is fused...

Page 41: ...rmer Common for Smoke Detector Communication Wire Communication Wire LC 5000 Control Board Smoke Detector 24V to Outdoor Air Humidity Sensor Ground Remote Indoor Humidity Sensor Zone 2 Remote Indoor H...

Page 42: ...r closed during normal operations Below 60 F Dewpoint Below 80 Relative Humidity Description Default Setpoint Temperature at local remote main sensor Temperature Setpoint 77 F Heating Setpoint 60 F Te...

Page 43: ...l require no field set up However the default setpoints and their ranges are easily viewed and adjusted from the controller display The program and operating parameters are permanently stored on FLASH...

Page 44: ...4 Pressing the ENTER key during the 1 hour period will deactivate COMFORT MODE Status Screen The STATUS screen is the default start up screen and also the return screen after 5 minutes of no activity...

Page 45: ...to Service Settings menu press ENTER key 3 Press UP or DOWN arrow keys to get to Control Setting menu press ENTER key 4 Cursor will be flashing in upper left corner of screen Press ENTER key to scrol...

Page 46: ...Enter an offset of 3 0 F to display the temperature correctly An offset of 9 9 F to 9 9 F can be entered Resetting Controller Model Serial Numbers 1 Go to Factory menu press ENTER key 2 Go to Factory...

Page 47: ...as been covered in this manual is not recommended CAUTION 4 Go to Analog Inputs press ENTER key 5 To enable Zone 2 and Zone 3 temperature sensors move cursor to desired zone by pressing the ENTER key...

Page 48: ...ily 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 l...

Page 49: ...R key to access that menu Press the ESCAPE key or MENU key to return to the STATUS screen from the Main Menu Status Screen The STATUS screen is the default start up screen and also the return screen a...

Page 50: ...ing Run Test Identifying a Unit Address 1 Go to On Off Unit menu 2 Screen will display individual address of wall mount unit Manual Override Outputs Blower 1 Go to Technician menu press ENTER key 2 Go...

Page 51: ...ition to ON and press ENTER key 6 Verify heater ON status 7 Repeat Steps 1 6 to enable Stage 2 heat Before enabling Stage 2 heater make sure the Stage 2 heater option is enabled under Unit Set Up The...

Page 52: ...lay on make for initial start up or anytime power is interrupted for a minum 2 minutes plus 10 of the red dial setting There is no delay during routine operation of the unit The compressor control mod...

Page 53: ...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 4...

Page 54: ...d MODEL RATED ESP MAX ESP FREE COOLING RATED FULL LOAD COOLING CFM ELECTRIC HEAT AIRFLOW W48A W48L 0 20 0 50 1800 1800 1800 W60A W60L 0 20 0 50 1800 1800 1800 W72A W72L 0 20 0 50 1800 1800 1800 FIGURE...

Page 55: ...NAL BLOCK FILTER SWITCH TOGGLE BRACKET GROUND PLC CONTROLLER BLOCK TOGGLE SENSOR TERMINAL L1 25 AMP CABLE WIRE SHEILD TERMINAL EVAP TEMP CABLE DUCT TRANSFORMER BLOCK BASE MONITIOR PHASE MODULE ASSEMBL...

Page 56: ...applicable 115 L3 Low Ambient Control opt L2 122 L3 Treminal T3 119 Compressor T2 Contactor L1 119 Y Outdoor Fan Capacitor T1 L2 L3 Red L1 L2 L1 Red 50 hz only Low 100 Red Yout C Phase Monitor Outdoo...

Page 57: ...dditional wall mount units 1 Disable system from LC controller see Advanced Programming section 2 Turn off AC breakers at wall mount units 3 Check inlet sides of condenser and evaporator coils for obs...

Page 58: ...r if the PLC controller board is defective Check if the connection is ok Reconnect the cable If the controller board is defective replace it High Temperature Alarm Alarm is reset automatically Occurs...

Page 59: ...ne 2 remote indoor temperature humidity sensor wiring Replace the Zone 2 remote indoor temperature humidity sensor Zone 3 Remote Indoor Temperature Sensor Failed Alarm B004 The alarm is activated if t...

Page 60: ...has failed The condenser fan speed controller has failed Check the condenser fan status while the high pressure is outside the normal setting Replace the condenser fan Replace the condenser low ambien...

Page 61: ...ensor is faulty a sensor wire is loose or an out of range value is read Check the outdoor temperature sensor wiring Check temperature vs resistance of temperature sensor see Table 2 5 on page 52 Repla...

Page 62: ...Manual 2100 642 Page 62 of 82...

Page 63: ...Manual 2100 642 Page 63 of 82 SECTION 3 APPENDIX...

Page 64: ...egrees Current outdoor air humidity for unit address displayed Blower On Off Current blower status for unit address displayed Damper Open Current damper status for unit address displayed 17 28 Last ho...

Page 65: ...int ZONE 1 HEAT 52 75 60 Heating setpoint ZONE 2 COOL 65 90 77 Cooling setpoint ZONE 2 HEAT 52 75 60 Heating setpoint ZONE 3 COOL 65 90 77 Cooling setpoint ZONE 3 HEAT 52 75 60 Heating setpoint Setpoi...

Page 66: ...Zone Temp 1 Current value if applicable Remote Zone Temp 1 Current value if applicable Remote Zone Temp 2 Current value if applicable Remote Zone Temp 3 Current value if applicable Indoor Humidity Zon...

Page 67: ...rs COMPRESSOR STAGE 1 Run Hours 000H Displays number of run hours Number Starts 00000 Displays number of unit starts COMPRESSOR STAGE 2 Run Hours 000H Displays number of run hours Number Starts 00000...

Page 68: ...one 1 Enable On Off On Type Normal Hi Res Normal Ohm x 5 4 20ma Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 0 10VDC Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 0 1V...

Page 69: ...to 3276 8 Offset 99 9 to 99 9 SPKP0087TO Offset 99 9 to 99 9 nu10 Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 10T170 Offset 99 9 to 99 9 50T90 Offset 99 9 to 99 9 NTCHT Offset 99 9...

Page 70: ...3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 0 10VDC Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 0 1VDC Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 PT1000 Offse...

Page 71: ...9 9 Max 9999 9 to 9999 9 Offset 99 9 to 99 9 Current Value Out of Range Alarm Will show if input out of range Power Delay 0 999 seconds 5 seconds Power up delay Run Delay 0 999 seconds 5 seconds Units...

Page 72: ...45 Band 1 999 20 Modulating Setup Humidifier Zone 2 Setpoint 1 999 45 Band 1 999 20 Modulating Setup Humidifier Zone 3 Setpoint 1 999 45 Band 1 999 20 Setpoint FREECOOL Enthalpy Dry Bulb None Enthalp...

Page 73: ...1 Heat UP DIFFERENTIAL 99 9 to 99 9 deg 2 DOWN DIFFERENTIAL 99 9 to 99 9 deg 2 DELAY UP 0 to 9999 sec 110 DELAY DOWN 0 to 9999 sec 60 SETPOINT 60 Control Dead Band Zone 2 Cool UP DIFFERENTIAL 99 9 to...

Page 74: ...N 999 9 to 999 9 Value entered to command point Value Current I O Value Remote Sensor 1 MANUAL CONTROL On Off Off MANUAL POSITION 999 9 to 999 9 Value entered to command point Value Current I O Value...

Page 75: ...Yes Duration 0 999 sec 30 Voltage 0 10 V 2 5 CONTROL DEADBAND ZONE 1 COOL Direction Direct Reverse Direct Stages 0 99 4 Up Differential 99 9 to 99 9 2 Down Differential 99 9 to 99 9 2 Delay Up 0 999...

Page 76: ...irection Direct Reverse Direct Stages 0 99 2 Up Differential 99 9 to 99 9 2 Down Differential 99 9 to 99 9 2 Delay Up 0 999 sec 60 Delay Down 0 999 sec 60 Setpoint 77 CONTROL DEADBAND ZONE 3 HEAT Dire...

Page 77: ...Setpoint 0 99 55 Differential 0 9 9 5 Above Setpoint Delay 0 999 sec 120 Below Setpoint Delay 0 999 sec 180 MODULATING SETUP HUMIDIFIER ZONE 1 Cntrl DIR REV BOTH P PID P I Rev P Band 0 999 9 20 DeadB...

Page 78: ...IT ON OFF By Digit Input On Off Off By Supervisor On Off Off By pLan Network On Off Off By Schedule On Off Off CONFIGURATION UNIT CONTROL Custom 1 On Off Off Custom 2 On Off Off Custom 3 On Off Off Cu...

Page 79: ...HM x 1 Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 OHM x 5 Min 3276 8 to 3276 7 0 Max 3276 8 to 3276 8 100 Offset 99 9 to 99 9 0 nu13 Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset...

Page 80: ...its Temp Other Pressure Temp Remote Zone 1 Same as Zone Temp 1 above Remote Zone 2 Same as Zone Temp 1 above Remote Zone 3 Same as Zone Temp 1 above Humidity Zone 1 Enable On Off On Type Normal Hi Res...

Page 81: ...fset 99 9 to 99 9 0 nu13 Min 3276 8 to 3276 7 Max 3276 8 to 3276 8 Offset 99 9 to 99 9 nu12 Min Max 3276 8 to 3276 7 Offset 3276 8 to 3276 8 SPKP0087T0 99 9 to 99 9 Offset nu10 99 9 to 99 9 Min Max 32...

Page 82: ...above Humidity Zone 3 Same as Humidity Zone 1 above Digital Inputs Smoke Detector Enable On Off Action Open Closed Delay 0 999 sec Relay Outputs Not configurable Analog outputs Not configurable FACTOR...

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