INSTALLATION INSTRUCTIONS
& REpLACEMENT pARTS LIST
MD4000 SERIES SOLID STATE
DUAL UNIT LEAD/LAG CONTROLLER
for use with H-Series
Wall Mount Air Conditioners
with F & G Spyder™ Economizers only
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Manual No.:
Supersedes:
File:
2100-574
NEW
Vol. III Tab 19
07-05-12
Since 1914...Moving ahead, just as planned.
Date:
Page
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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.
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
Standard for the Installation............... ANSI/NFPA 90A
of Air Conditioning and
Ventilating Systems
ANSI
American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Standard for Warm Air Heating ......... ANSI/NFPA 90B
and Air Conditioning Systems
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
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2100-574
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The MD4000 is equipped with the B alarm board.
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.
** ImPOrtant **
The equipment covered in this manual is to be installed by
trained, experienced service and installation technicians.
Please read entire manual before proceeding.
There is an Ethernet based remote communication
option that can be either factory or field installed. See
section on Communication Module.
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.
cOntrOller certIFIcatIOns
The MD4000 main controller board, alarm board,
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:
General
These instructions explain the operation, installation
and troubleshooting of the MD4000 Series controller.
All internal wiring is complete. Only attach low
voltage field wiring to designated terminal strips.
MD4000 Series
Master Controller
The MD4000 is for use with units with economizers.
This device complies with FCC Rule Part 15, Subpart
B, Class A. Operation is subject to the following two
conditions:
Each unit should be sized to handle the total load of the
structure if 100% redundancy is required.
The MD4000 controller is suitable for both 50 and 60
HZ operation. See Controller Programmable Features
and Default Settings.
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.
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 must be used with units with economizers and
both units be equipped alike.
This ISM device also complies with Canadian ICES – 001.
Bard Manufacturing Company, Inc.
Bryan, OH 43506
The MD4000 controller is configured for alternative
(lead/lag/lead/lag) sequence, which is default setting.
The MD4000 works in conjunction with the Economizer
Logic Modules to provide room temperature control
based on the DC amp load that the building is using.
The Economizer Logic Modules, in the air conditioner,
control the cooling stages and functions. The MD4000
controls the heating stages, lead lag operation and
alarming operation for the system.
Manual 2100-574
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If the differential is greater than 12F then the controller
will check to determine the on-board sensor is reading a
temperature that is between the SP (set-point) plus 12F
and the SP minus the DB (dead-band) minus 12F. If it is
the on-board sensor will become the valid sensor reading
and the controller will ignore the local sensor reading. If
it is not then the controller will still use the local sensor
reading. This is to add additional level 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. 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.
sPecIFIcatIOns/Features FOr
mD4000-b cOntrOller
MD4000 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)
•Heating Control stages:
1 for each A/C unit
•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
•On-Off differential: 2F (1C) is standard, 4F (3C) when
“excessive cycling” mode is enabled
•Comfort setting, Heating 68F(20C), for 1 hour
•Dead band (difference between cooling and heating set
points): 2F to 40F (1.1C to 22.2C)
•Fire/smoke interface: standard NC circuit jumper, remove
for connection to building system control, shuts down both
A/C units immediately
•Memory: EEPROM for set point and changeable
parameters (maintains settings on power loss)
•Space temperature sensors: 1 local is standard, will accept up
to 2 optional 25' remote sensors, Bard part number 8612-023.
When multiple sensors are used, temperatures are averaged
•Controller Enclosure: 20-gauge pre-painted steel, 9.25"W
x 20.875"H x 3.00"D, hinged cover, twenty four (24) .875"
diameter electrical knockouts
The controller is designed to accept 1 or 2 additional
sensors and those have 25-foot leads. The Bard part
number for the optional sensor with 25-foot leads is
8612-023. These can be installed as required in the
structure to address hot spots, barriers to airflow, etc.
It is recommended that the sensor lead wires be installed
in conduit for protective purposes.
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.
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 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.
•LEDs for basic controller: Lead unit, Heating Stages 1 – 4
•Six (6) Push-button controls: On/Off switch-Change lead
unit-Increase & Decrease set points-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 four (4) feet above the floor-away from drafts &
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 & top of the controller.
If multiple temperature sensors are used, the High and
Low temperature alarms will be governed by the average
of the connected sensors.
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. Any differential of +/- 12F
between the on-board and local sensor will cause the
controller to use the local sensor as its point of reference.
Manual
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basIc mD4000 cOntrOller
InPut/OutPut sPecIFIcatIOns
lOcateD In the mD4000 Panel bOx
Unit #1 terminal Block
mD4000 cOntrOller cOnnectIOns
R – 24VAC hot from Unit
C – 24VAC common from Unit
Y – Compressor Signal to Unit
F – Economizer Shutdown Output to Economizer
A – Compressor Signal from Economizer
4 – Dirty Filter Alarm from Unit
5 – Dirty Filter Alarm from Unit
6 – Signal Common for F
8 – Economizer Fail from Unit
9 – Economizer Fail from Unit
10 – Emergency Vent Output to Economizer
41 – To Unit 2, 43
42 – To Unit 2, 44
43 – To Unit 2, 41
44 – To Unit 2, 42
45 – To Unit 2, 45 DCA Input
46 – To Unit 2, 46 DCA Input
47 – To Unit 1 Display
Located on Main Controller Board
Unit #1
C – 24VAC common
R – 24VAC hot
G – fan (Form A, NO)
W – heat (Form A, NO)
C – 24VAC common
R – 24VAC hot
Unit #2
G – fan (Form A, NO)
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
48 – To Unit 1 Display
Rem 1 Optional remote indoor sensor
CU – copper, AG – silver
Polarity sensitive
Rem 2 Optional remote indoor sensor
CU – copper, AG – silver
Polarity sensitive
H1-H2 Humidity controller input
Requires optional controller
Field installed
NOTE:
Unit #2 terminal Block
Sensors are
solid state,
not RTD.
R – 24VAC hot from Unit
C – 24VAC common from Unit
Y – Compressor Signal to Unit
F – Economizer Shutdown Output to Economizer
A – Compressor Signal from Economizer
4 – Dirty Filter Alarm from Unit
5 – Dirty Filter Alarm from Unit
6 – Signal Common for F
Use Bard
sensors only.
Advance Input used to remotely toggle lead/lag change
8 – Economizer Fail from Unit
9 – Economizer Fail from Unit
10 – Emergency Vent Output to Economizer
41 – To Unit 1, 43
(a) These connections require either jumper or Normally
Closed (NC) relay contact at the Fire/Smoke and Generator
interface for Controller to function.
42 – To Unit 1, 44
43 – To Unit 1, 41
44 – To Unit 1, 42
45 – To Unit 1, 45 DCA Input
46 – To Unit 1, 46 DCA Input
47 – To Unit 2 Display
48 – To Unit 2 Display
Note: All alarm and output relays are dry contacts rated
1A @ 24 VAC.
Gen Run/Econ Shutdown terminal Block(a)
Gen Run Input
Note: All alarm relay outputs have 10-second delay
before issuing to protect against nuisance alarm signals.
Economizer Fail terminal Block
Alarm Output
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 2100-574
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sPecIFIcatIOns/Features FOr
lOW vOltaGe FIelD WIrInG
The MD4000 is powered from the air conditioners that
it is controlling, 24 VAC (18-32V) low voltage only.
mD4000-b & -bc cOntrOller alarms
Inputs
Lockout 1
Lockout 2
2, 3 – input from HVAC #1
2, 3 – input from HVAC #2
Circuitry in the MD4000 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 MD4000 and the other air conditioner
are unaffected and will continue to operate normally.
Outputs
Smoke/Fire
Lockout 1
Form C (SPDT)
Form C (SPDT)
Refrigerant alarm HVAC #1
Form C (SPDT)
Refrigerant alarm HVAC #2
Form C (SPDT)
Power loss HVAC #1
Form C (SPDT)
Power loss HVAC #2
Form C (SPDT)
Low temperature alarm
Form C (SPDT)
High temperature alarm #1
Form C (SPDT)
High temperature alarm #2
Form C (SPDT)
Controller failure alarm
E, F - Form A (NO)
See note (b)
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.
Lockout 2
Power Loss 1
Power Loss 2
Low Temp
High Temp 1
High Temp 2
Controller
Econ 1
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.
Econ 2
E, F - Form A (NO)
See note (b)
Form C (SPDT)
2nd-stage cooling alarm
2nd Stage (c)
(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.
2nd Compressor Form A (NC)
Dirty Filter
Form A (NC)
4, 5 – Input from Unit
Economizer Fail Form A (NC)
8, 9 – Input from Unit
Manual
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blOWer OPeratIOn
FIre suPPressIOn cIrcuIt
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 on the lead unit
operates continuously. 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.
To disable the MD4000 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.
When any of the stages are satisfied, the stage LED
will blink for ten (10) seconds before the stage is
actually turned off.
staGInG DelaY PerIODs
The following delays are built in for both cooling & heating:
aDvance (sWaP) leaD/laG unIt
Feature
Stage 1 – 0 seconds for blower (if not already on as
continuous)
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. This function can also be done remotely by
closing a contact across the Advance terminals on the
main board.
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
accelerate tImer Feature
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.
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 2100-574
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General PrOGrammInG OvervIeW
mD4000 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.
Set Points will return to the programmed settings automatically after 1 hour.
Pressing the Comfort button during the 1 hour period will deactivate the Set Point change.
The temperature display will flash the current temperature while in override mode.
Program Button
1.
2.
Press the Program button and release it when the message “Prog” appears on the display.
Refer to Programming Instructions and follow these commands to change from Default settings.
Advance/Change/Save Button
1.
2.
3.
Press and release the Advance button to swap lead and lag unit positions.
When in Program mode the Down and Up buttons are used to scroll through the programming steps.
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.
5.
6.
To change the setting press the Change button and the display will stop flashing, allowing change to the setting.
Use Down or Up arrows to change setting as desired, and press the Save button and proceed as desired.
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 /
Description
range / choice
Default
Display
LSEn
SP
Temperature at local (main) sensor
—
65 to 90F (18 to 32C)
2 to 40F (1 to 24C)
—
—
77F (25C)
27F (15C)
—
Cooling set point temperature
db
Deadband between cooling SP and heating set point
Temperature at remote sensor 1 location, if connected
Temperature at remote sensor 2 location, if connected
Continuous blower operation
r1
r2
—
—
cFAn
deg
None, Lead, Both
F or C
Lead
F
Controller system operates in F or C
Alternating Lead-Lag-Lead-Lag sequence or Non-Alternating Lead-Lead-Lag-Lag sequence —
Yes = Alternating
Alt
LLCO
HP
Not Used
Yes
7
1 - 30 days, or 0 for
disabled
Lead-Lag changeover time (Days)
Heat pump logic enabled — only for 1-stage heat pumps and forces Lead-Lag sequence
(overrides a Non-Alt setting)
Not Used
No
Cbd5
OFde
crun
Unit 1 and 2 blowers automatically both run if delta T >5F between any 2 connected sensors
3-minute lead unit & 4-minute lag unit off-delay enabled
Minimum 3-minute compressor runtime enabled
Low temperature alarm setpoint
Yes or No
Not Used
Yes
No
Not Used
No
LoAL
HAL1
HAL2
Not Used
45F (7.2C)
90F (32C)
95F (35C)
High temperature alarm level #1 setpoint
70F to 120F (21 to 49C)
70F to 120F (21 to 49C)
High temperature alarm level #2 setpoint
If locked, display will show
Locd if changes attempted
Locd
Controller is locked and no changes can be made. Consult building authority.
Unlocked
Inter-Stage Differential
ISd2
ISd3
ISd4
From Stage 1 to Stage 2
Not Used
Not Used
Not Used
4
2
2
From Stage 2 to Stage 3
From Stage 3 to Stage 4
On/Off Differential (Hysterisis)
CSon
CSoF
Turn "On" above SP for Stage 1 Cooling
Not Used
Not Used
2
Turn "Off" below SP for Stage 1 Cooling
-4
Stage 2, 3 and 4 Cooling automatically set same as Stage 1 decisions
All Heating Stages are equal -/+ on & off differential
HSoo
CoPr
-1/+1 or -2/+2
Not Used
-2/+2
1
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
Manual
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1. Air Conditioners with Electric Heat
heatInG seQuence OF OPeratIOn
1st stage heating set point is the dead-band (db) below
the 1st stage cooling set point (the SP entered into the
program). The dead-band is adjustable from 2-40F, and
factory default is 27F.
2nd stage heating set point will operate at same inter
stage differential as set for cooling mode.
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.
MD4000
decides Lead
unit
MD4000-BCESDC/MD4000-BESDC
W/ AC UNITS W/ DC CONTROL
ECONOMIZERS
Spyder 1 is lead
Signals Spyder2
as lag.
Spyder 2 is lead
Signals Spyder1
as Lag
If OAT <= SP-MTD
and Enthalpy is below
curve(if equipped
No
Is OAT suitable
for Cooling
Yes
DC Amp load is read and
converted to building load
with the equation DCA *
Determine Building
106.4-.2455 = BTUH
Load
OAT = Outdoor Air Temperature
BL = Building Load
MAT will be adjusted to take
Calculate adjusted
MDT = Minimum Temperature Differential
RT = Room Temperature
SP = Setpoint
into account deviation from
building Load
(BL)
setpoint
BL+((RT-SP)*Airflow*1.2)
AC = Available Cooling
Calculate
Available Cooling
Available cooling =( SP-
(AC) for 1 econ
MTD-OAT)*1.08*Airflow
No
Calculate
If AC > BL
Yes
Available cooling
for 2 econ
No
Calculate MAT
Start Econ 1
Start Econ 2
Start Blower 2
Allow econ
operation with
Compressor
If AC*2 > BL
Yes
Yes
No
Calculate MAT
Start Econ 1
Stop Econ 2
Stop Blower 2
Calculate MAT
Start Econ 1
Start Econ 2
Start Blower 2
Stop Econ 1
Stop Econ 2
Stop Blower 2
Is RT
No
above or
below SP
No
Is RT
above SP
Yes
Yes
Start Lead
Compressor
Start Lead Blower
Yes
No
No
Is RT
Above ALarn
Setpoint
Is RT
Below SP
Is 2nd comp
Allowed
NO
Yes
Yes
Stop Lead
Start Lag
Compressor
Compressor
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For Vista or Windows 7:
sPecIFIcatIOns FOr OPtIOnal remOte
cOmmunIcatIOn bOarD
1. Open Control Panel, click Network & Internet.
2. Click Network & Sharing Center.
3. Click Local Area Network link.
4. Click Properties.
5. Highlight Internet Protocol Version 4 (TCP/
IPV4) and select Properties.
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. 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.
6. Change the addresses as follows:
IP address:
Subnet mask:
Default gateway:
Preferred DNS server:
Alternate DNS server:
192.168.1.50
255.255.255.0
192.168.1.1
192.168.1.10
192.168.1.11
Required Input Connections to the CB4000 (these are
all internal connections from either the alarm board or
main controller board):
7. Click OK and close all windows.
8. Start your browser, enter the CB4000’s default IP
address 192.168.1.67 and hit Enter.
9. The MD4000 log-in page should appear.
1. Fire/smoke connection from MD4000 main
controller board.
2. Refrigerant lockout inputs.
3. If economizers are used an additional 24V signal
wire is required from each air conditioner to the
controller system.
4. Communication cable from CB4000 plugs into
phone jack connection on main MD4000 controller
board.
LOG IN PAGE
1. Type in “Admin” for the user name and “Bard” for
the password. These are case sensitive. Hit “Log In”.
2. Click the “System Setup” button.
SYStEM SEtUP PAGE
Note: If the remote user is on a different subnet than the
CB4000 it is recommended that Static IP Addressing be
used rather than DHCP.
OPERAtING SYStEM
No special software is required to access the system.
The CB4000 has a default address, simply follow these
instructions:
IF YOUR NETWORK USES STATIC IP ADDRESSING
1. Enter the correct address information provided by
your IT department and click the “Save Config”
button.
2. The assumption is that the new IP address has
already been configured into the network to get
through any firewall(s).
tO ACCESS tHE SYStEM
1. Connect CAT 5 or CAT 6 Ethernet cable from
computer to Ethernet port on the CB4000.
2. Change your computer’s IP address as shown
below to gain initial access to the CB4000.
3. Disconnect the Ethernet cable from the computer
and plug into your router.
4. Change your computer system’s IP address back to
their previous settings from Note 1.
NOTE 1: Record your computer’s current IP settings
BEFORE making any changes. You will need to reset
back to these original settings once you’ve assigned an IP
address to the CB4000.
5. Type the new IPaddress into the browser and make
any changes to the MD4000 system before logging
out.
For XP or Windows 2000:
1. Open Control Panel, double click Network
Connections.
2. Double click Local Area Connection on the
General tab and select Properties.
3. Using the General tab, scroll to Internet
Protocol (TCP/IP).
4. Highlight Internet Protocol (TCP/IP) and select
Properties.
5. Change the addresses as follows:
IF YOUR NETWORK USES DHCP
1. Check the “Enable DHCP” box.
2. Click “Save Config” box (it will take several
seconds before you receive a message that you are
now offline.At this point the unit is now running in
DHCP mode).
3. Change your computer system’s IP address back to
their previous settings from Note 1.
4. Type CB4000 in the browser’s URL address bar to
access the CB4000.
IP address:
Subnet mask:
Default gateway:
Preferred DNS server:
Alternate DNS server:
192.168.1.50
255.255.255.0
192.168.1.1
192.168.1.10
192.168.1.11
6. Click OK and close all windows.
7. Start your browser, enter the CB4000’s default IP
address 192.168.1.67 and hit Enter.
NOTE 2: If you need to get back to the CB4000 default
IP setting simply hold the reset button next to the phone
jack for 5+ seconds, then release.
8. The MD4000 log-in page should appear.
Manual
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2100-574
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4. General Alarm Status:
USER PAGE
a. Fire/Smoke, Clear or Alarm
b. Low Temp, Clear or Alarm
c. High Temp #1, Clear or Alarm
d. High Temp #2, Clear or Alarm
e. Controller Failure, Clear or Alarm
1. The designated Admin person can assign up to 9
additional users and set-up as Admin, Write or
Read authority.
2. User Name and password must be assigned, each
must be at least 3 characters long, and are case
sensitive.
3. Only “Admin” can add, change or delete users and
has access to all controller pages.
4. “Write” can make changes to the controller
settings and operating characteristics, and has
access to only Log In, System Status, Setpoints,
and Log Out pages.
SEtPOINtS PAGE (Note: “Read” level authority
can view this screen but cannot make any changes.
“Admin” and “Write” authority can make changes)
1. General Setpoints
a. On initial installation and start-up all
selectable characteristics are set to factory default
settings.
b. Each of these points has a drop-down menu
for ease of use.
5. “Read” can only view Status and Setpoints pages
and cannot make any changes.
2. Alarm Board Setpoints
SYStEM StAtUS PAGE
a. Low temperature alarm setpoint
b. High temperature alarm #1 setpoint
c. High temperature alarm #2 setpoint
3. System Overrides
1. This page shows the overall HVAC status of:
a. Active cooling or heating stages or
dehumidification mode (requires humidity
sensor)
a. System 1 Heating Override
b. System 2 Heating Override
c. Turn Power On to the System (Note: Cannot
remotely turn the controller system Off)
d. Lock/Unlock Controller
e. Advance Lead to Lag Unit
f. Comfort Mode
g. Restore System Defaults
b. Active controller outputs (blower, 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. If economizers are used, this will show if the
economizers are on or off.
2. General status of:
h. Reset Controller. There are built-in routines to
prevent the controller system from getting
“locked up”, but this also allows a manual
remote reset as a backup before having a
service call to the site.
a. Backup Generator Active or not (if tied to
generator run controls to inhibit lag unit
operation during generator run)
b. Alarm board connected or not
c. Controller system Locked or Unlocked
d. Comfort mode Active or not
LOG OUt BUttON
1. Clicking this button will automatically log you
off the controller remote access.
2. To log back in will require entering assigned IP
address into your browser and entering valid
User Name and Password.
3. Temperatures:
a. Average temperature (if more than ones sensor
used, if not will read same as Local sensor)
b. Local sensor at controller
c. Remote 1 or Remote 2 if connected
CONNECt tO NEtWORk
1. After initial set-up using laptop computer,
disconnect computer cable from the Ethernet port
and connect the CAT 5 or CAT 6 network cable.
cb4000 cOmmunIcatIOn bOarD
2. Remote access is now available using the assigned
IP address and valid User Name and Password
(case sensitive).
RESET BUTTON TO RETURN TO DEFAULT CONTROLLER SETTINgS
PHONE jACk
CONNECTION
TO MAIN
CONTROLLER
BOARD
IP DEFAULT ADDRESS RESET
ETHERNET PORT
Manual 2100-574
Page 12 of 23
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A normally closed (NC) dry contact as part of generator
controls is required. These contacts must open when
the generator is started, and such action will signal the
MD4000 controller to this condition and disable lag
air conditioner run function and close economizers if
active.
cOntrOller WIrInG
The MD4000 can be used for controlling two (2) air
conditioners with economizers.
securItY (lOckInG) Feature
The MD4000 controller can be locked such that
unauthorized persons cannot make any changes
to temperature set points or any other selectable
parameters of the controller system.
A wire jumper is factory-installed across the Generator
Run / Economizer Shutdown terminals. To utilize
the generator run feature, remove the jumper from
Generator Run / Economizer Shutdown, and connect
the generator normally closed (NC) contacts that will
open-on-run generator condition to the Generator Run /
Economizer Shutdown terminals.
The ON/OFF and Comfort buttons remain fully
active for their normal intent. The Advance/Change/
Save button remains active for the Advance feature
only, which allows the position of the lead and lag air
conditioners to be swapped (reversed). The Program
button remains partially active - allowing the review
of temperature sensor(s) actual reading of temperature,
and the current settings/choices that have been chosen.
However, no changes can be made when the controller
is locked, and if the change button is pressed when in
the Program mode, the display will come up showing
“Locd” instead of flashing the selectable choices for
that parameter. The default (DEF) reset capability is
also disabled when the controller is in locked mode.
backuP Dc POWer cOnnectIOn
There are input connections available for -24VDC or
-48VDC (-20 to -56V) backup power connection. Making
this connection will maintain microprocessor operation,
front panel display, LED signaling, and alarm relay
operation during periods of commercial power outages
and when no standby generator is available. This circuit
is protected by a replaceable .5A (500mA) 250V fuse.
IMPORtANt: The shelter DC battery power must
be connected to the controller and wired as shown in
controller wiring diagrams.
Locking and Unlocking the MD4000 Controller:
The backup DC power connection is polarity
sensitive. If polarity is reversed, the controller will
not function on backup power, no display and no
alarm functions will be evident.
1. Locking the controller requires using 3 buttons
while the controller is in the normal operating (run)
mode.
2. Press and hold the Advance/Change/Save button
and the Up and Down arrow buttons simultaneously
for 20 seconds until the display shows “Locd”.
3. To unlock the controller, press the Change, Up and
Down arrow buttons simultaneously for 20 seconds
until the display reads “uLoc”.
GeneratOr run / ecOnOmIzer
shutDOWn Feature
If desired, the MD4000 controller can be signaled
from a standby generator system to lockout (disable
operation of the) lag air conditioning system and close
economizers if active. This is sometimes mandated if
the generator size is not sufficient to handle the building
load (amperage) and that of both air conditioning
systems.
Manual
Page
2100-574
13 of 23
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table 1
hOOk-uP DIaGram selectIOn table — reFerence FIGure 1 shOWn
mD4000-b
newer ecOnWmt economizer —
no communication board
system
type
model
series
mD4000-bc newer ecOnWmt economizer
with cb4000 communication board
A/C with 1-Stage Compressor
H**A / H**L
1
2
FIGure 1
mD4000-b cOntrOller cOnnectIOns
1-staGe (h**a/h**l serIes) aIr cOnDItIOners
WIth (ecOnWmt) ecOnOmIzers
AC UNIT 1
3
4
48
47
46
45
44
43
42
41
MD4000 UNIT 1
MD4000
TERMINAL BLOCK
46
45
44
43
42
41
R
C
Y
F
DISPLAY 1
DISPLAY 2
1
2
3
4
1
2
3
4
R
C
Y
F
A
4
R
C
RED/WHITE
BLACK/WHITE
BLUE
27
NO
9
YELLOW
YELLOW/WHITE
PURPLE
A
4
26
DIRTY FILTER
ALARM (NC)
28
BLUE/WHITE
YELLOW/RED
BROWN/WHITE
ORANGE
5
5
30
6
6
MD4000
MAIN BOARD
10
7
8
8
9
15
R
ECON FAIL
ALARM (NC)
9
UNIT 1
SPYDER ECON
C
W
Y1
Y2
G
W
Y1
Y2
G
E
UNIT 1
NOTE: DC BACK-UP POWER
IS POLARITY SENSITIVE AND
+
_
48VDC
2
MUST BE CONNECTED AS SHOWN
OR CONTROLLER WILL NOT
3
OPTIONAL
48VDC
OPERATE ON DC POWER ONLY
10
1
E
F
2
3
E
F
2
3
1
LOCKOUT ALARM
1
LOCKOUT ALARM
ALARM
BOARD
2
REFRIGERANT PRESSURE LOCKOUT
ALARM - REQUIRES "J" CONTROL MODULE IN
A/C UNITS
FIRE/SMOKE
ALARM CIRCUIT
"NC" CONTACTS -
OPEN ON ALARM
1
GEN RUN ALARM/
ECON SHUTDOWN
FIRE/
SMOKE
THE "E" AND "F" CONNECTION FOR EMERGENCY
VENTILATION ARE AVAILABLE
2
3
NC CONTACTS
OPEN ON ALARM
NC CONTACTS
OPEN ON ALARM
F1
F2
REMOVE
JUMPER
2 COMP RUN ALARM
TERMINAL BLOCK
USE SHIELDED CABLE OR EQUIVALENT.
CONNECT SHIELD AT SPYDER ONLY
REMOVE
JUMPER
AC UNIT 2
R
G
1
E
Y2
Y1
W
C
2
UNIT 2
3
10
G
Y2
Y1
W
NOTE: ALL SENSORS ARE
POLARITY SENSITIVE. COPPER
LEAD MUST CONNECT TO
CU, AND SILVER MUST
LEAD TO AG
CU COPPER
LOCAL
REM 1
REM 2
AG
SILVER
MD4000 UNIT 2
TERMINAL BLOCK
UNIT 2
SPYDER ECON
CU COPPER
AG SILVER
9
9
8
OPTIONAL FIELD INSTALLED
25 FOOT TEMPERATURE
SENSORS, BARD PART
NUMBER 8612-023
ECON FAIL
ALARM (NC)
15
30
ORANGE
8
YELLOW/RED
CU COPPER
AG SILVER
7
6
10
28
26
9
BROWN/WHITE
BLUE/WHITE
PURPLE
6
5
5
DIRTY FILTER
ALARM (NC)
G2
G1
4
4
YELLOW/WHITE
YELLOW
A
F
Y
C
R
A
F
OPTIONAL FIELD INSTALLED
HUMIDITY
H1
H2
NO
27
C
HUMIDITY CONTROLLER
"NO" CONTACTS - CLOSE ON RISE
BLUE
Y
C
CONTROLLER
BLACK/WHITE
RED/WHITE
ADVANCE
R
R
41
42
43
44
45
41
42
43
44
45
46
46
47
48
4
3
MIS-3092 A
Manual 2100-574
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FIGure 2
mD4000-bc cOntrOller cOnnectIOns
1-staGe (h**a/h**l serIes) aIr cOnDItIOners
WIth (ecOnWmt) ecOnOmIzers
anD WIth alarm bOarD & cb4000 cOmmunIcatIOn bOarD
AC UNIT 1
3
4
48
47
46
45
44
43
42
41
MD4000 UNIT 1
MD4000
TERMINAL BLOCK
46
45
44
43
42
41
R
C
Y
F
DISPLAY 1
DISPLAY 2
1
2
3
4
1
2
3
4
R
C
RED/WHITE
BLACK/WHITE
BLUE
R
C
Y
F
A
4
27
NO
9
YELLOW
YELLOW/WHITE
PURPLE
A
4
26
28
30
10
15
DIRTY FILTER
ALARM (NC)
BLUE/WHITE
YELLOW/RED
BROWN/WHITE
ORANGE
5
5
MD4000
MAIN BOARD
6
6
7
8
8
9
R
ECON FAIL
ALARM (NC)
9
UNIT 1
SPYDER ECON
C
W
Y1
Y2
G
W
Y1
Y2
G
E
UNIT 1
NOTE: DC BACK-UP POWER
IS POLARITY SENSITIVE AND
MUST BE CONNECTED AS SHOWN
OR CONTROLLER WILL NOT
OPERATE ON DC POWER ONLY
+
_
48VDC
2
3
OPTIONAL
48VDC
10
1
E
F
2
3
E
F
2
3
1
LOCKOUT ALARM
1
LOCKOUT ALARM
ALARM
2 BOARD
REFRIGERANT PRESSURE LOCKOUT
ALARM - REQUIRES "J" CONTROL MODULE IN
A/C UNITS
FIRE/SMOKE
ALARM CIRCUIT
"NC" CONTACTS -
OPEN ON ALARM
1
CB4000
NO
C
GEN RUN ALARM/
ECON SHUTDOWN
FIRE/
SMOKE
THE "E" AND "F" CONNECTION FOR EMERGENCY
VENTILATION ARE AVAILABLE
REMOVE
JUMPER
2
3
NC CONTACTS
OPEN ON ALARM
NC CONTACTS
OPEN ON ALARM
NC
1-3
2-3
3-3
1
F1
F2
2 COMP RUN ALARM
TERMINAL BLOCK
USE SHIELDED CABLE OR EQUIVALENT.
CONNECT SHIELD AT SPYDER ONLY
REMOVE
JUMPER
AC UNIT 2
2
3
R
G
1
E
2
Y2
Y1
W
C
UNIT 2
3
10
G
NOTE: ALL SENSORS ARE
POLARITY SENSITIVE. COPPER
LEAD MUST CONNECT TO
CU, AND SILVER MUST
LEAD TO AG
Y2
Y1
W
CU COPPER
LOCAL
REM 1
REM 2
AG
SILVER
MD4000 UNIT 2
TERMINAL BLOCK
UNIT 2
COPPER
SILVER
CU
AG
SPYDER ECON
9
9
8
OPTIONAL FIELD INSTALLED
25 FOOT TEMPERATURE
SENSORS, BARD PART
NUMBER 8612-023
ECON FAIL
ALARM (NC)
15
30
ORANGE
8
CU COPPER
AG SILVER
YELLOW/RED
7
6
10
28
26
9
BROWN/WHITE
BLUE/WHITE
PURPLE
6
5
5
DIRTY FILTER
ALARM (NC)
G2
G1
4
4
A
F
Y
C
R
YELLOW/WHITE
YELLOW
A
F
OPTIONAL FIELD INSTALLED
HUMIDITY
H1
H2
NO
27
C
HUMIDITY CONTROLLER
"NO" CONTACTS - CLOSE ON RISE
BLUE
Y
C
CONTROLLER
BLACK/WHITE
RED/WHITE
ADVANCE
R
R
41
42
43
44
45
41
42
43
44
45
46
46
47
48
4
MIS-3093
3
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ecOnOmIzer FaIlure alarm
alarm WIrInG
Upon failure of either economizer to open on command
or close on command, the Economizer Failure Alarm
will open normally closed contacts to signal the
failure. To utilize this feature, terminals 8 & 9 must be
connected to the shelter alarm panel.
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.
A normally closed economizer fail alarm is available on
terminals 8 & 9 of the Unit 1 & 2 terminal blocks.
When multiple alarms are grouped together and issued
as a single alarm, there will 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 shown on the LED
display on the face of the controller.
DIrtY FIlter alarm
A normally closed dirty filter alarm is available on
terminals 4 & 5 of the Unit 1 & 2 terminal blocks.
2-cOmPressOr run alarm
Note: All alarm and output relays are Form C (SPDT)
If both compressors are running at the same time, the
2-Compressor Run Alarm will open indicating this
condition.
dry contacts rated 1A @ 24 VAC.
Note: All alarm relay outputs have 10-second delay in
acutally issuing to protect against nuisance alarm signals.
The Power Loss 1, Power Loss 2 and controller alarm
relays are all “reverse actuated”, which means they
are continuously energized (the NO contact is closed)
and switched to NC position upon alarm condition.
Therefore, it is important to closely follow the alarm
board connection diagrams that follow.
Note: the alarm LeD display board is shipped
uninstalled 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.
Any alarm feature that is not desired can simply be
ignored (not connected).
NOtE: the LED display board can be replaced if
needed independently of the alarm board. Bard
part number is 8612-022.
alarm leD DIsPlaY bOarD
Note: The LED display board is polarized and will
only fit in one direction as shown. It must be fully
inserted in order for the controller to function properly.
MIS-2042
Manual 2100-574
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2nD staGe cOOlInG alarm
emerGencY ventIlatIOn seQuence
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. If this is the
case, or possibly when additional heat load is added,
using the 2nd stage cooling alarm will cause nuisance
alarm conditions.
For units with economizers, there are two (2)
emergency ventilation sequences designed into the
controller. Both require the -B alarm board and
connection of terminals E and F from the air conditioner
24V terminal block to the matching terminals on the
alarm board.
Note: The E and F wiring connections at the 24V
terminal block in the A/C units are different for
older style EIFM economizers than for newer style
ECONWMT economizers. Refer to the appropriate
Controller Connection diagrams - See Table 1.
Note: For units with 2-stage compressors, the dual
stage cooling alarm activates on cooling Stage 3
initiation. Menu Step 23, CoPr, must be set to “2” for
this to occur, otherwise alarm will activate on cooling
call Stage 2 causing nuisance alarm.
Sequence one requires a refrigerant pressure alarm,
coupled with high temperature alarm condition No. 1
(HAL 1 set point). If both of these conditions occur,
the economizer in the air conditioner that issued the
refrigerant alarm will drive open to ventilate the building.
For installations where it is known that there is 100%
redundancy (one air conditioning unit can handle 100% of
the load 100% of the time) use of the 2nd Stage Cooling
Alarm is a method to issue an alarm signal that the lead
air conditioner is down (or not delivering full capacity)
and that the lag air conditioner is now operating.
Sequence two (HAL 2 set point) is activated by high
temperature alarm No. 2, and will initiate even without
a refrigerant pressure alarm signal. Both economizers
will be activated to provide emergency ventilation.
This strategy help protect against building overheating
if air conditioner(s) are inoperative for non-pressure
related reasons (bad compressor, contactor, run
capacitor, etc.).
reFrIGerant Pressure alarms
Air conditioners with “J” control module are equipped
with an alarm relay that is activated upon high or low
refrigerant pressure lockout conditions. Connecting
terminals 2 and 3 from the air conditioner 24V terminal
block to the matching terminals 2 and 3 on the alarm
board will allow these alarms to function.
sPYDer ecOnOmIzer DIsPlaYs
The two (2) displays on the front of the MD4000 are for
remotely monitoring and programming the 100% fresh
air Spyder economizers in the units. See Instruction
Manual 2100-576 for details.
Manual
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FIGure 3
alarm bOarD cOnnectIOns
FOr nOrmallY clOseD "nc" OPen-On-alarm strateGY
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.
Manual 2100-574
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FIGure 4
alarm bOarD cOnnectIOns
FOr nOrmallY OPen "nO" clOse-On-alarm strateGY
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.
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To change the setting of any step, press the CHANGE
button and the display will stop flashing, allowing
change to the setting by using the DOWN or UP
arrows. When desired setting is reached, press the
SAVE button, and proceed as desired. When done with
programming changes, press the PROGRAM button
until display stops flashing and room temperature
display is shown. If no buttons are pushed within thirty
(30) seconds, the controller will automatically revert
back to “RUN” mode.
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.
To reset all controller settings to the factory default
values, press the PROGRAM button for 10 seconds
until display reads dEF.
NOTE: When the controller has the security locking feature enabled, no changes to any selectable features can be
made, and the default reset feature is also locked out. All of the programmable features/settings can be reviewed
using the Program button and Up or Down arrows, but any attempt to change settings using the Change button will
result is display showing “Locd” indicating controller is locked. See section on Security (Locking) Feature.
See next page for Programmable Features, Default Settings and MD4000 front panel label layout.
Note: When using the controller buttons to review settings or making changes, push and hold the buttons for
approximately 1 second or until the display changes.
Quickly pushing or jabbing the buttons will not allow the controller to respond.
Manual 2100-574
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D
See displays above
h
N/A - See Operating Manual
N/A - See Operating Manual
27F/15C
N/A - See Operating Manual
N/A - See Operating Manual
N/A - See Operating Manual
N/A - See Operating Manual
LEAD
N/A - See Operating Manual
N/A - See Operating Manual
N/A - See Operating Manual
N/A - See Operating Manual
7961-762
Manual
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2100-574
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FIGure 5
Parts lIst DescrIPtIOn DIaGram
20
6
18
10
8
1
11
19
14
13
17
3
4
15
5
12
7
2
9
SEXP-648
Manual 2100-574
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Parts List
Dwg.
no.
Part no.
Description
mD4000-b mD4000-bc ab3000-b
cb4000
1
2
3
4
5
6
7
8
9
127-423-4
8612-038
8612-021
8612-022
113-456-4
152-515-4
8611-099
5400-002
8612-023
7961-762
8611-006
8612-035
8201-015
8201-071
8607-030
113-461-4
8201-062
8611-094
8607-033
8301-043
Control Box
Controller Board
Alarm Board B
Alarm Display
Support Bracket
Control Box Door
LTF Fitting
X
X
X
X
X
X
X
X
X
X
2
X
X
X
X
X
X
X
X
X
X
2
X
X
Hinge
Sensor
10
11
12
13
14
15
16
17
18
19
20
Label/keypad
ground Lug
Communication Board
Relay
X
2
X
2
3
2
1
2
2
2
2
Relay
3
Terminal Block
Alarm Bracket
Relay
2
1
2
Light
2
Terminal Block
Display
2
2
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