McQuay CMU Installation Manual

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Horizontal Water Source Heat Pump Units

Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Transportation & Storage . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning & Flushing System . . . . . . . . . . . . . . . . . . . . 7

Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ty pical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 10-13

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 16

Thermostat Connections. . . . . . . . . . . . . . . . . . . . 17-18

Options for Mark IV/AC Units . . . . . . . . . . . . . . . . 19-22

Field Installed Options on MicroTech Units . . . . . . . . 23

Troubleshooting WSHP . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation & Maintenance Data

Group: WSHP

Part Number: 106581301

Date: March 2002

IM 526-15

Page 2 / IM 526

Transportation & Storage

Installation

General

Upon receipt of the equipment, check carton for visible damage. Make a notation on the shipper’s delivery ticket before signing. If there is any evidence of rough handling, immediately open the cartons to check for concealed damage. If any damage is found, notify the carrier within 48 hours to establish your claim and request their inspection and a report. The Warranty Claims Department should then be contacted.

Do not stand or transport the machines on end. For stor-

ing, each carton is marked with “up” arrows.

In the event that elevator transfer makes up-ended positioning unavoidable, absolutely ensure that the machine is in the normal upright position for at least 24 hours before operating.

Temporary storage at the job site must be indoors, completely sheltered from rain, snow, etc. High or low temperatures naturally associated with weather patterns will not harm the conditioners. Excessively high temperatures, 140°F (60°C) and higher, may deteriorate certain plastic materials and cause permanent damage.

1. To prevent damage, this equipment should not be operated for supplementary heating and cooling during the construction period.

2. Inspect the carton for any specific tagging numbers indicated by the factory per a request from the installing contractor. At this time the voltage, phase and capacity should be checked against the plans.

3. Check the unit size against the plans to ensure unit installation is in the correct location.

4. After removing the carton, remove the hanger kit from the fan housing.

5. Before installation, check the available ceiling height versus the height of the unit.

6. Note the location and routing of water piping, condensate drain piping, and electrical wiring. The locations of these items are clearly marked on submittal drawings.

7. The installing contractor will find it beneficial to confer

with piping, sheet metal, ceiling and electrical foremen before installing any conditioners.

8. Remove all shipping blocks in the fan wheel.

9. Change the airflow direction from straight discharge to end discharge or vice versa before the unit is installed in the ceiling. Refer to the section in this bulletin for instructions.

10. We recommend that the contractor cover the conditioners with plastic film to protect the machines during finishing of the building. This is critical while spraying fireproofing material on bar joists, sandblasting, spray painting and plastering. If plastic film is not available, the shipping carton may be modified to cover the units during construction.

11. On units with spring mounted compressors, remove the hold-down bolt from the bottom of the unit before starting compressor.

Model Nomenclature

Product Catagory

W = WSHP

Product Identifier

See box below

Design Series

1 = A Design 4 = D Design 2 = B Design 5 = E Design 3 = C Design

Nominal Capacity

007 = 7,000 015 = 15,000 009 = 9,000 019 = 19,000

012 = 12,000 etc....

Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and are experienced with this type of equipment. Caution: Sharp edges are a potential injury hazard. Avoid contact with them.

W CDD 1 009 D Z

Coil Options

None

Voltage

E=208/230-60-1 F=208/23-60-3 J=265-60-1 K=460-60-3 L= 575-60-3 M=230-50-1 N = 380-50-3

McQuay Product Identifiers

CDD = Ceiling mtd./DDC Controls/Ext. Range/Less Board CME = Ceiling mtd./Mark IV/Ext. Range CDE = Ceiling mtd./DDC Controls/Ext. Range CMG = Ceiling mtd./Mark IV/Geothermal CDL = Ceiling mtd./DDC Controls/Std. Range/Less Board CMS = Ceiling mtd./Mark IV/Std. Range CDS = Ceiling mtd./DDC Controls/Std. Range CMU = Ceiling mtd./Mark IV/European Spec.

UNIT DIMENSIONS (mm)

SIZE A B C D E F G 006 – 012 965 921 914 584 632 683 546 015 – 019 1067 1022 1016 610 660 711 571 024 – 030 1114 1069 1067 660 711 762 622 036 – 042 1245 1200 1194 660 711 762 622 048 – 060 1524 1480 1473 711 762 813 673

Figure 1A. Hanger bracket detail, sizes 007 thru 060

Figure 1B. Hanger bracket detail, sizes 070 thru 120

UNIT DIMENSIONS (INCHES)

SIZE A B C D E F G H 007 – 012 38 36 321⁄2 201⁄4 22 181⁄2 34 20 015 – 030 44 42 381⁄2 201⁄4 22 181⁄2 40 20 035 – 042 50 48 441⁄2 201⁄4 22 181⁄2 46 20 048 & 060 545⁄16 525⁄16 48 285⁄32 30 26 50 28 070 – 120 See Figure 1B

IM 526 / Page 3

Unit Location

1. Locate the unit in an area that allows for easy removal of the filter and access panels. Leave enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connections.

2. The contractor should make sure that adequate ceiling panel access exists, including clearance for hanger brackets, duct collars and fittings at water and electrical connections.

3. Allow adequate room below the unit for a condensate trap and do not locate the unit above pipes.

4. Each unit is suspended from the ceiling by four threaded rods. The rods are attached to the unit corners by a hanger bracket through a rubber isolator. Caution: Do not use rods smaller than specified below. The rods must be securely anchored to the ceiling or to the bar joists.

Figure 1C. Unit sizes 007 thru 060

Figure 1E. Unit sizes 070 thru 120

5. Each unit is furnished with a hanger kit. The kit is shipped unassembled and includes hanger brackets, rubber isolators, washers, bolts and lock washers. Lay out the threaded rods per the dimensions in Figures 1A and 1B. Assemble the hangers to the unit as shown in Figures 1C, 1D and 1E. Securely tighten the brackets to the unit.

6. When attaching the hanger rods to the unit, a double nut is recommended since vibration could loosen a single nut. The installer is responsible for providing the hex nuts when installing hanger rods.

7. Leave minimum 3" (76 mm) extra threaded rod below the double nuts or minimum 3" (76 mm) clearance between top of unit and ceiling above to facilitate top panel removal for servicing

8. The unit should be pitched towards the drain in both directions to facilitate condensate removal.

UNIT DIMENSIONS (mm)

SIZE A B C D E F G H 007 – 012 965 914 826 514 559 470 864 508 015 – 030 1118 1067 978 514 559 470 1016 508 035 – 042 1270 1219 1130 514 559 470 1168 508 048 & 060 1380 1329 1219 715 762 660 1270 711 070 – 120 See Figure 1B

Hanger bracket dimensions

⁄8" Threaded Rod

(By Others)

Vibration Isolator

Washer

Hex Nuts (By Others)

Bolt & Lock Washer

By McQuay International

By Others

Hanger bracket dimensions for WCMU type units

5/8

” Threaded Rod (

By Others)

Coil

Airflow

Fan

Assembly

Control

Box

Comp

C G

1-15/16"

(51 mm)

1-7/8"

(48 mm)

Fan

Assembly

Airflow

Coil

80" (2032 mm)

82" (2083 mm)

44"

(1118

mm)

42"

(1067

mm)

(51 mm)

Comp

Control Box

(51 mm)

Page 4 / IM 526

h =

amount to provide a grip for removing.)

2. Adjust sheave pitch diameter for desired speed by opening moving parts by half or full turns from closed position. Do not open more than five full turns.

3. Replace external key “E” and securely tighten setscrews “B” over key and setscrews “C” into keyway in fixed half of the sheave.

4. Put on belts and adjust belt tension to 4 lbs. ±0.7 lbs. (18N ±3N) for a

⁄2" to 3⁄4" (13 mm to 19 mm) belt deflec-

tion height.

5. To determine the deflection distance from normal position, use a straightedge or stretch a cord from sheave to sheave to use as a reference line. On multiple-belt drives an adjacent undeflected belt can be used as a reference.

6. Future adjustments should be made by loosening the belt tension and increasing or decreasing the pitch diameter of the sheave by half or full turns as required. Readjust belt tension before starting drive.

7. Be sure that all keys are in place and that all setscrews are tight before starting drive. Check setscrews and belt tension after 24 hours service.

8. When new V-belts are installed on a drive, the initial tension will drop rapidly during the first few hours. Check tension frequently during the first 24 hours of operation. Subsequent retensioning should fall between the minimum and maximum force.

Unit Motor RPM Factory Motor Sheave Size HP Range Setting (RPM) Position

⁄2 756 – 902 785 4 Turns Open

070

3 907 –1081 904 5 Turns Open 1

⁄2 698 – 832 858 11⁄2 Tu rns Open

090

3 907 –1081 904 5 Turns Open 3 756 – 901 814 3 Turns Open

120

5 907 –1081 904 5 Turns Open

Air Balancing

Unit sizes 070 thru 120 are supplied with a variable pitch motor sheave to aid in airflow adjustment. They are set at the factory according to Chart 1 shown below.

When the final adjustments are complete, the current draw of the motors should be checked and compared to the full load current rating of the motors. The amperage must not exceed the service factor stamped on the motor nameplate.

Upon completion of the air balance, it is a common industry recommendation that the variable pitched motor sheave be replaced with a properly sized fixed sheave. A matching fixed sheave will provide longer belt and bearing life and vibration free operation. Initially, it is best to have a variable pitched motor sheave for the purpose of air balancing, but once the balance has been achieved, fixed sheaves maintain balancing and alignment more effectively.

Adjustment (See Figure 2)

1. All sheaves should be mounted on the motor or driving

shaft with the setscrew “A” toward the motor

2. Be sure both driving and driven sheaves are in alignment

and that shafts are parallel.

3. Fit internal key “D” between sheave and shaft, and lock

setscrew “A” securely in place.

Adjusting

1. Loosen setscrews “B” and “C” in moving parts of sheave

and pull out external key “E”. (This key projects a small

Single Groove

Key E projects to provide a grip for removing.

Figure 3. Drive belt adjustment

Figure 2.

Chart 1A. 60 Hz

()

Where: t=Span length, inches (mm)

C=Center distance, inches (mm) D=Larger sheave diameter, inches (mm) d=Smaller sheave diameter, inches (m) h=Deflection height, inches (mm)

Note: The ratio of deflection to belt span is 1:64.

Chart 1B. 50 Hz

Filter Access

t = C2–

D-d

Unit Motor RPM Factory Motor Sheave Size HP Range Setting (RPM) Position

070 11⁄2 756 – 901 786 4 Turns Open 090 11⁄2 720 – 860 858 11⁄2 Tu rns Open 120 3 756 – 902 815 3 Turns Open

Each unit is shipped with a filter bracket for side filter removal. For bottom removal push the filter up into top bracket to gain clearance of bottom bracket and remove the filter. Also, a sheet metal duct filter retainer can be fabricated when return air duct work is used.

Span Length (t)

fle

tio



IM 526 / Page 5

Air Discharge Conversion

Unit sizes 007 thru 060 can be shipped as straight discharge air or end discharge air arrangement. Most likely, the unit will have to be converted from straight discharge to end discharge. To accomplish this:

1. Remove top panel.

2. Remove the access panel to the fan motor. Remove the piece of insulation at the bottom on the side of the bottom panel.

3. Remove the fan discharge panel, rotate it 180 degrees, and move it to the other side. In other words, with

straight air discharge the housing is bottom horizontal and with an end discharge the housing is top horizontal.

4. Remove the three bolts holding the fan motor on and rotate it so that the motor oilers are in the up position.

5. Install insulation base panel below new access panel location.

6. Reinstall the top panel.

7. Reinstall the piece of insulation and the access panel.

Ductwork & Attenuation

Discharge ductwork is normally used with these conditioners. Return air ductwork may also be required.

All ductwork should conform to industry standards of

good practice as described in the ASHRAE Systems Guide.

The discharge duct system will normally consist of a flexible connector at the unit, a transition piece to the full duct size, a short run of duct, an elbow without vanes, and a trunk duct teeing into a branch duct with discharge diffusers as shown in Figure 4. The transition piece must not have angles totaling more than 30° or severe loss of air performance can result. Do not connect the full duct size to the unit without using a transition piece down to the size of the discharge collar on the unit. With metal duct material, the sides only of the elbow and entire branch duct should be internally lined with acoustic fibrous insulation for sound attenuation. Glass fiber duct board material is more absorbing and may permit omission of the canvas connector.

The ductwork should be laid out so that there is no line of sight between the conditioner discharge and the distrib-

ution diffusers.

Return air ducts can be brought in through a low side wall filter-grille and then up through the stud pieces to a ceiling plenum or through air ceiling filter-grilles. The ceiling filter-grille must not be placed directly under the conditioner.

Return air ductwork can be connected to the standard filter rack. See Figure 5 (side filter removal shown). The filter rack can be installed for bottom filter removal or side filter removal by locating the brackets. For side filter removal the brackets should be located on the bottom, left side, and top. For bottom filter removal the brackets should be mounted on the left side top and right side with the spring clips supporting the filter.

Do not use sheet metal screws directly into the unit cabinet for connection of supply or return air ductwork, especially return air ductwork which can hit the drain pan or the air coil.

Figure 4.

Figure 5. Filter rack/return air duct collar

2x2 Ft. Diffuser (Example Only)

Branch Duct Internally Lined With Acoustic Fibrous Insulation

Trunk Duct

Square Elbow

Canvas Collar

Heat Pump

Transformation

Piece

Discharge Collar

On Heat Pump

Both Sides Internally Lined With Acoustic Fibrous Glass Insulation

Suggested Duct Layout For

Multiple Diffuser Application

Standard 1" (25mm) and 2" (51 mm) for sizes 007 thru 060

Standard 2" (51 mm) for sizes 070 thru 120

Ventilation may require outside air. The temperature of the ventilation air must be controlled so that mixture of outside air and return air entering the conditioner does not exceed conditioner application limits. It is also typical to close off the ventilation air system during unoccupied periods (night setback).

The ventilation air system is generally a separate build-

Ventilation Air

ing subsystem with distribution ductwork. Simple introduction of the outside air into each return air plenum chamber reasonably close to the conditioner air inlet is not only adequate, but recommended. Do not duct outside air directly to the conditioner inlet. Provide sufficient distance for thorough mixing of outside and return air. See Operating Limits on page 10.

Page 6 / IM 526

Electrical Data

1. Verify the compatibility between the voltage and phase of the available power and that shown on the unit serial plate. Line and low voltage wiring must comply with local codes or the National Electrical Code, whichever applies.

2. Apply correct line voltage to the unit. A

⁄8" (22mm) hole

and/or a 1

⁄8" (29 mm) knockout is supplied on the side of the unit. A disconnect switch near the unit is required by code. Power to the unit must be sized correctly and have dual element (Class RK5) fuses or an HACR circuit

General

breaker for branch circuit overcurrent protection. See the nameplate for correct ratings.

3. Three phase 50 cycle units, 380/50/3, require a neutral wire for 230/50/1 power to the fan circuit.

4. Connect the thermostat/subbase wiring with the power “off ” to the unit.

5. Field supplied relays installed on the input terminals

W1, W2, Y1, Y2 or G may introduce electrical noise. Never install relay coils in series with the inputs.

230 Volt Operation

Fan Assembly

All 208-230 volt single-phase and three-phase units are factory wired for 208 volt operation. For 230 phase operation, the line voltage tap on the 24 volt transformer must be

All fan motors are multi-speed, PSC type with integral mounting brackets and thermal overload protection. The motor is isolated from the fan housing for minimum vibration transmission. Fan motors have a terminal strip on the motor body for simple motor speed change without going back to the control box. All the fan/motor assemblies have a removable orifice ring on the housing to accommodate

changed. Disconnect and cap the red lead wire and interchange it with the orange lead wire on the primary of the 24 volt transformer.

Figure 6. Sizes 006 through 012

Piping

1. All units should be connected to supply and return piping in a two-pipe reverse return configuration. A reverse return system is inherently self-balancing and requires only trim balancing where multiple quantities of units with different flow and pressure drop characteristics exist in the same loop. Check for proper water balance by measuring differential temperature reading across the water connections. To insure proper water flow, the differential flow should be 10°F to 14°F (5°C to 8°C) for units in cooling mode.

A direct return system may also work acceptably, but proper water flow balancing is more difficult to achieve and maintain.

2. The piping can be steel, copper or PVC.

3. Supply and return runouts usually join the unit via short lengths of high pressure flexible hose which are sound attenuators for both unit operating noise and hydraulic pumping noise. One end of the hose should have a swivel fitting to facilitate removal for service. Hard piping can also be brought directly to the unit. This option is not recommended since no vibration or noise attenuation can be accomplished. The hard piping must have unions to facilitate unit removal. See Figure 7 for typical piping setup.

4. Some flexible hose threaded fittings are supplied with sealant compound. If not, apply Teflon tape to assure a tight seal.

5. Supply and return shutoff valves are required at each conditioner. The return valve is used for balancing and should have a “memory stop” so that it can always be closed off but can only be reopened to the proper position for the flow required.

6. No unit should be connected to the supply and return piping until the water system has been cleaned and flushed completely. After the cleaning and flushing has taken place, the initial connection should have all valves wide open in preparation for water system flushing.

7. Units with water regulating valves need to have the capillary routed outside the unit through a notch in the access panel. Be sure to install the split rubber grommet (supplied) in this notch to protect the capillary and check to ensure that all other parts of the capillary do not contact other steel or copper parts. Install the valve in the return water line.

8. Condensate piping can be steel, copper or PVC. Each unit includes a condensate connection.

motor and fan wheel removal without disconnecting the ductwork. The fan housing protrudes through the cabinet allowing adequate material for connection of flexible duct. Each model unit is shipped from the factory for maximum performance and minimum sound requirements. Fan sound levels and performance can be effected by external static pressure

Figure 6a. Sizes 015 through 060

FAN

MOTOR

FAN

MOTOR

WHITE (COMMON)

BROWN (CAPACITOR)

BLUE (HIGH SPEED) SIZE 012

RED (LOW SPEED) SIZES 006-009, 015, 024

WHITE (COMMON)

BROWN (CAPACITOR)

BLACK (HIGH SPEED) SIZES 042, 060

BLUE (MED. SPEED) SIZES 030, 048

RED (LOW SPEED) SIZES -015, 019, 024, 036

IM 526 / Page 7

9. The condensate disposal piping must have a trap. The piping must be pitched away from the unit not less than

⁄4" per foot (21 mm per meter) (see Figure 8). Generally, the condensate trap is made of copper and soldered on the unit. A piece of vinyl hose from the trap to the drain line is used for simple removal. A complete copper or PVC condensate system can also be used. Union fittings in the copper lines should be applied to facilitate removal. Factory supplied condensate hose assemblies have pipe thread fittings to facilitate connection of a flexible vinyl or steel braided hose.

Figure 7. (Sizes 007 through 060 shown)

Figure 8.

Ball Valves

Supply

Riser

Return

Riser

Condensate

Riser

Supply Air

Optional Cleanout

⁄2"

(38 mm)

⁄2"

(38 mm)

Hanger Kits (4)

Flex Hoses

Electrical Access Panel

⁄4" Per Foot (21 mm Per Meter)

10. Do not locate any point in the drain system above the drain connection of any unit.

11. Automatic flow controlled devices must not be installed prior to system cleaning and flushing.

12. A high point of the piping system must be vented.

13. Check local code for the need for dielectric fittings.

Cleaning & Flushing System

1. Prior to first operation of any conditioner, the water circulating system must be cleaned and flushed of all construction dirt and debris.

If the conditioners are equipped with water shutoff valves, either electric or pressure operated, the supply and return runouts must be connected together at each conditioner location. This will prevent the introduction of dirt into the unit. See Figure 9.

Figure 9.

2. Fill the system at the city water makeup connection with all air vents open. After filling, close all air vents.

The contractor should start main circulator with the pressure reducing valve open. Check vents in sequence to bleed off any trapped air, ensuring circulation through all components of the system.

Power to the heat rejector unit should be off, and the supplementary heat control set at 80°F (27°C).

While circulating water, the contractor should check and repair any leaks in the piping. Drains at the lowest point(s) in the system should be opened for initial flush and blowdown, making sure city water fill valves are set to make up water at the same rate. Check the pressure gauge at pump suction and manually adjust the makeup to hold the same positive steady pressure both before and after opening the drain valves. Flush should continue for at least two hours, or longer if required, to see clear, clean drain water.

3. Shut off supplemental heater and circulator pump and open all drains and vents to completely drain down the system. Short circuited supply and return runouts should now be connected to the conditioner supply and return connections. Do not use sealers at the swivel flare connections of hoses.

4. Trisodium phosphate was formerly recommended as a cleaning agent during flushing. However, many states and localities ban the introduction of phosphates into their sewage systems. The current recommendation is to simply flush longer with warm 80°F (27°C) water.

Return Runout

Supply Runout

Mains

Flexible Hose

Runouts Initially Connected Together

Note: Do not overtorque fittings. The maximum torque without damage to fittings is 30 foot pounds. If a torque wrench is not available, use as a rule of thumb, finger-tight plus one quarter turn. Use two wrenches to tighten the union, one to hold the line and one for simultaneous tightening of the nut.

Page 8 / IM 526

Start-up

1. Open all valves to full open position and turn on power to the conditioner.

2. Set thermostat for “Fan Only” operation by selecting “Off” at the system switch and “On” at the fan switch. If “Auto” fan operation is selected, the fan will cycle with the compressor. Check for proper air delivery.

3. For those units that have two-speed motors, reconnect for low speed operation if necessary.

4. Set thermostat to “Cool.” If the thermostat is an automatic changeover type, simply set the cooling temperature to the coolest position. On manual changeover types additionally select “Cool” at the system switch.

Again, many conditioners have time delays which protect the compressor(s) against short cycling. After a few minutes of operation, check the discharge grilles for cool air delivery. Measure the temperature difference between entering and leaving water. It should be approximately 1

⁄2 times greater than the heating mode temperature difference. For example, if the cooling temperature difference is 15°F (8°C), the heating temperature difference should have been 10°F (5°C). Without automatic flow control valves, target a cooling temperature difference of 10°F to 14°F (5°C to 8°C). Adjust the combination shutoff/balancing valve in the return line to a water flow rate which will result in the 10˚F to 14°F (5°C to 8°C) difference.

5. Set thermostat to “Heat.” If the thermostat is the automatic changeover type, set system switch to the “Auto” position and depress the heat setting to the warmest selection. Some conditioners have built-in time delays which prevent the compressor from immediately starting. With most control schemes, the fan will start immediately. After a few minutes of compressor

operation, check for warm air delivery at discharge grille. If this is a “cold building” start-up, leave unit running until return air to the unit is at least 65°F (18°C).

Measure the temperature difference between entering and leaving air and entering and leaving water. With entering water of 60°F to 80°F (16°C to 27°C), leaving water should be 6°F to 12°F (3.3°C to 6.6°C) cooler, and the air temperature rise through the machine should not exceed 35°F (19°C). If the air temperature exceeds 35°F (19°C), then the water flow rate is inadequate.

6. Check the elevation and cleanliness of the condensate line. If the air is too dry for sufficient dehumidification, slowly pour enough water into the condensate pan to ensure proper drainage.

7. If the conditioner does not operate, check the following points: a. Is supply voltage to the machine compatible? b. Is thermostat type appropriate? c. Is thermostat wiring correct?

8. If the conditioner operates but stops after a brief period: a. Is there proper airflow? Check for dirty filter, incor-

rect fan rotation (3-phase fan motors only), or incorrect ductwork.

b. Is there proper water flow rate within temperature

limits? Check water balancing; backflush unit if dirtclogged.

9. Check for vibrating refrigerant piping, fan wheels, etc.

10. Do not lubricate the fan motor during the first year of operation as it is prelubricated at the factory.

11. Field supplied relays installed on the input terminals

W1, W2, Y1, Y2 or G may introduce electrical noise. Never install relay coils in series with the inputs.

5. Refill the system with clean water. Test the water using litmus paper for acidity, and treat as required to leave the water slightly alkaline (pH 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Do not use automotive grade antifreeze.

Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system wide degradation of performance and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life or caus-

es premature failure. A SystemSaver

from McQuay International should be employed to continuously remove solids as the system operates. Contact your local representative for further information on this device.

6. Set the loop water controller heat add setpoint to 70°F (21°C) and the heat rejection setpoint to 85°F (29°C). Supply power to all motors and start the circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season) and air vented and loop temperatures stabilized, each of the conditioners will be ready for check, test and start-up, air balancing, and water balancing.

IM 526 / Page 9

Operating Limits

Extended Range

Standard Units

Units

Cooling Heating Cooling Heating

Min. Ambient Air 50˚F/10˚C 50˚F/10˚C 40˚F/5˚C 40˚F/5˚C Normal Ambient Air 80˚F/27˚C 70˚F/21˚C 80˚F/27˚C 70˚F/21˚C Max. Ambient Air 100˚F/38˚C 85˚F/29˚C 100˚F/38˚C 85˚F/29˚C Min. Ent. Air ➀ ➁ 50˚F/10˚C 50˚F/10˚C 50˚F/10˚C 40˚F/5˚C Normal Ent. Air, 80/67˚F 70˚F 80/67˚F 70˚F

dw/wb 27/19˚C 21˚C 27/19˚C 21˚C Max. Ent. Air 100/83˚F 80˚F 100/83˚F 80˚C

db/wb ➀ ➁ 38/28˚C 27˚C 38/28˚C 27˚C

➀ At ARI flow rate. ➁

Maximum and minimum values may not be combined. If one value is at maximum or minimum, the other two conditions may not exceed the normal condition for standard units. Extended range units may combine any two maximum or minimum conditions, but not more than two, with all other conditions being normal conditions.

This equipment is designed for indoor installation only. Sheltered locations such as attics, garages, etc., generally will not provide sufficient protection against extremes in

Environment

Standard units

Units are designed to start and operate in an ambient of 40°F (5°C), with entering air at 40°F (5°C), with entering water at 70°F (21°C), with both air and water flow rates used in the ARI Standard 320-86 rating test, for initial startup in winter.

Note: This is not a normal or continuous operating con-

dition. It is assumed that such a start-up is for the purpose of bringing the building space up to occupancy temperature.

Extended range units

Extended range heat pump conditioners are designed to start and operate in an ambient of 40°F (5°C), with entering air at 40°F (5°C), with entering water at 40°F (5°C), with both air and water at flow rates used in the ARI Standard 320-86 rating test, for initial start-up in winter.

Note: This is not a normal or continuous operating con-

dition. It is assumed that such a start-up is for the purpose of bringing the building space up to occupancy temperature.

temperature and/or humidity, and equipment performance, reliability, and service life may be adversely affected.

Air and water limits

Water enthalpy

Extended Range

Standard Units

Units

Cooling Heating Cooling Heating

Min. Ent. Water ➀ ➁ 55°F/13°C 55°F/13°C 40°F/5°C 40°F/5°C Normal Ent. Water 85°F/29˚C 70˚F/21°C 85°F/29˚C 70˚F/21°C Max. Ent. Air ➀ ➁ 110°F/43˚C 90°F/32°C 110°F/43˚C 90°F/32°C

Additional Information For Initial Start-up Only

Operating voltages

115/60/1 . . . . . . . . . . . . . . . 104 volts min.; 127 volts max.

208-230/60/1 . . . . . . . . . . . 197 volts min.; 253 volts max.

265/60/1 . . . . . . . . . . . . . . . 238 volts min.; 292 volts max.

230/50/1 . . . . . . . . . . . . . . . 197 volts min.; 253 volts max.

460/60/3 . . . . . . . . . . . . . . . 414 volts min.; 506 volts max.

380/50/3 . . . . . . . . . . . . . . . 342 volts min.; 418 volts max.

575/60/3 . . . . . . . . . . . . . . . 515 volts min.; 632 volts max.

Note: Voltages listed are to show voltage range. However, units operating with overvoltage and undervoltage for extended periods of time will experience premature component failure. Three phase system unbalance should not exceed 2%.

Page 10 / IM 526

Typical Wiring Diagrams

Notes:

1. Unit is factory wired for 208V operation. If 230V power supply is used, transformer must be rewired by disconnecting the power lead from the red transformer primary wire and connecting the power lead to the orange transformer primary wire. Place an insulation cap on the red transformer primary wire.

2. All temperature and pressure switches are normally closed.

3. Component layout shown below is typical. Some components may not be used on this model or voltage.

4. Mark IV/AC controller board contains a static sensitive microprocessor. Proper grounding of field service personnel should be observed or damage to controller may result.

Figure 10. Mark IV/AC unit wiring diagram – single phase

COMPONENT LAYOUT

➀ COMPRESSOR CONTACTOR ➁ FAN CONTACTOR ➂ TRANSFORMER ➃ PC BOARD ➄ AUXILIARY RELAY ➅ CIRCUIT BREAKER

5. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other outputs are 24 VDC.

6. Field supplied relays installed on the input terminals (W1, W2, Y1 or

G) may interfere with proper unit operation. Never install relay coils in series with inputs.

7. For more information pertaining to the Mark IV/AC controller, refer to OM120.

*060 - Blk

048 - Red 042 - Blk 036 - Blk 030 - Blk

L1 L2

CAP

CC - Compressor Contactor HTR - Crankcase Heater

CAP - Motor Capacitor

Ground

Compr

Motor

Heater

CAP

Fan

Motor

(Optional)

Lo Temp

Hi Pressure

Lo Pressure

BK60

Reversing Valve Solenoid

BK61

Condensate

Sensor

RD 208V BR 265V

OR 240V

24VAC

Common

W1Y

COF

XFORMER

UAP

Fan

34 35

Compressor

Mark IV

Board

IM 526 / Page 11

Notes:

1. On 208/230V units, unit is factory wired for 208V operation. If 230V power supply is used, transformer must be rewired by disconnecting the power lead from the red transformer primary wire and connecting the power lead to the orange transformer primary wire. Place an insulation cap on the red transformer primary wire.

2. All temperature and pressure switches are normally closed.

Figure 11. Typical Mark IV/AC dual circuit wiring diagram

Compr

460 & 575V

Only

RD 208V

BK/RD 460V

BK 575V

OR 240V

Lo Press

Lo Temp

Hi Press

Solenoid

Fan Relay

MicroTech Controller

2524

14 1213 11 910 8 67534121011

69 E

L U P C73

12121212121212

Terminal Board #1

1st Option

(Factory Installed

See Note 3)

1110987654321

Discharge Air In

Discharge Air Com

Water Out In

Water Out Com

Aux Module DC +

Aux Module DC Com

Aux Module SEL 1

Aux Module SEL 2

Aux Module CLK

Aux Module XMT

Aux Module RCV

Lo Temp SRC

Condensate

Lo Press SIG

Lo Temp SIG

Lo Press SRC

RV Com

Hi Press SIG

Comp Com

RV Out

Fan Com

Comp Out

Fan Out

Remote DI SRC

Remote DI SIG

Spare Relay NC

Spare Relay Com

Spare Relay NO

RM Sensor LED

Tenant Override

RM Sensor In

RM Sensor Com

Lon Talk

24VAC Com

24V Gnd

24VAC

70 71 (See Note 3) 72 (See Note 3)

89674531

22 23

Fan Relay

460 & 575V Only

Fan

Motor

575V Only

12345

Cap

12 3

Condensate

Overflow

24VAC

Line

Compr

Contr

Discharge

Air

Water

Out

Fan

Motor

Cap

1 2

1 2 3 4 5 6 7

Auxiliary Module

(Optional)

321

L3L2L1

Terminal Board #2

Red Tape

End

Circut

Breaker

(optional)

Page 12 / IM 526

Figure 12. Typical MicroTech 2000 WSHP unit controller single circuit wiring diagram

Notes:

2. All temperature and pressure switches are normally closed.

3. Wires 71 and 72 used only on units with no factory installed options.

IM 526 / Page 13

Gnd Lug

126

PB1

123

T1L2T2L3T3

L1T1

22 23

Heater

(Ext. Rng. Only)

Heater

(Ext. Rng. Only)

Compr.

Mtr.

(50Hz Only)

L3 12 13

L3 14 15

24V

CCBR

12341234432143

J2 J1

J11 J10

Auxiliary

Module

MicroTech

Controller

J8 J4

21234567

5456

Disch

Air

Water

Out

RV1

3 & 5 HP Only

HP1

LP1

LT1

Condensate

Lo Temp SRC

Lo Temp SIG

Lo PRess SIG

Lo Press SRC

Hi Press SIG

RV Com

RV Out

Comp Com

Comp Out

Fan Com

Fan Out

24VAC

24 V Gnd

Remote DI SRC

Remote DI SIG

Spare Relay NC

Spare Relay NO

Spare Relay Com

RM Sensor LED

Tenant Override

RM Sensor In

RM Sensor Com

Lon Talk

24VAC Com

Aux Module DC Com

Aux Module DC +

Aux Module SEL 2

Aux Module SEL 1

Aux Module CLK

Aux Module RCV

Aux Module XMT

Discharge Air Com

Discharge Air In

Water Out Com

Water Out In

Terminal Board #2

Condensate

Overflow

141312 1110 987654321 111098 7

L U P C

6543

J1 J2

Terminal Board #1

1st Option

(Factory Installed

See Note 1)

123456789

2 345 6789101112

70 71 (See Note 1) 72 (See Note 1)

J6J5J4

RV2

LP2

LT2

HP2

T1 (75VA)

BK/RD 460V

OR 230V RD 208V BK 575V

VT 400V

(50Hz only)

Compr.

Mtr.

7 8

4 514

616

Fan Mtr.

24 (3 & 5 HP) 3 (1.5 HP

L2T2

Ext. Overloads

3 & 5 HP only

Red Tape End

Circut

Breaker

(optional)

Figure 13. Typical MicroTech WSHP unit controller dual circuit wiring diagram

Unit Operation

Two types of units are available: Mark IV/AC control units or units equipped with the new MicroTech 2000 Water Source Heat Pump Controller.

Mark IV/AC Control Units

The Mark IV/AC control circuit has built-in night setback operation. A “grounded’ signal to the “U” terminal on the low voltage terminal strip puts the unit into the unoccupied mode for night setback operation. Fan operation terminates and unit control reverts to the night setback terminal on the thermostat, W2; day heating and cooling operation is locked out. R-W2 energizes the compressor and reversing valve for heating operation. Night setback operation can be overridden for two hours by toggling the fan switch (intermittently closing the R to O terminals) on the Deluxe Auto Changeover thermostat. Day thermostat setpoints then control the heating and cooling operation. The Mark IV/AC control system also accommodates load shed and shutdown operation on receipt of a “grounded” signal to the “L” and “E” terminals, respectively, on the low voltage terminal strip.

Figure 15.

The P and C terminals of the Mark IV/AC board are used for pump restart. These terminals pass a voltage signal whenever the unit compressor is turned on. This signal is detected by a pump restart relay board providing a N.O. or N.C. set of contacts for heat pump loop circulation pump control. When used with the Loop Water Controller, the relay operation accommodates turning off circulation pumps during unoccupied periods with a safety override dependent, at minimum, on WSHP’s need. The P and C terminals may be “daisy chained” between 200 units. See page 22.

Field supplied relays installed on the input terminals W1, W2, Y1, Y2 or G may introduce electrical noise. Never install relay coils in series with the inputs.

To activate the unoccupied mode for units on the same clock schedule, a single wire can be “daisy chained” between units and simply grounded through the time clock contacts. The same system can also be done to activate the load shed and unit shutdown modes by running additional wires between units to ground.

Page 14 / IM 526

The Mark IV/AC circuit board is an optional control system with built-in features such as random start, compressor time delay, night setback, load shed, shutdown, condensate overflow protection, defrost cycle, brownout, and LED/fault outputs. Figure 10 shows the LED and fault output sequences.

The unit has been designed for operation with a 24 volt mercury bulb type wall thermostat or a microelectronic wall thermostat selected by the manufacturer. Do not operate the unit with any other type of wall thermostat.

Each unit has a printed circuit board control system. The low voltage output from the low voltage terminal strip can be either AC voltage or DC voltage to the wall thermostat. This is dependent on what terminals you use. R is A/C voltage output and F is D/C voltage output to the wall stat.

The 24 volt low voltage terminal strip is set up so R-G or F-G energizes the fan, R-Y1 or F-Y1 energizes the compressor for cooling operation, R-W1 or F-W1 energizes the compressor and reversing valve for heating operation. The reversing valve is energized in the heating mode. The circuit board has a fan interlock circuit to energize the fan whenever the compressor’s on if the thermostat logic fails to do so.

Remember the output to the wall stat can be AC current or DC current. Terminal (R) on the wall stat can be connected to terminal (R) on the PC board for AC voltage or to terminal (F) on the PC board for DC voltage.

AC current DC current

R to G = fan only F to G = fan only

R to Y1 = cooling F to Y1 = cooling

R to W1 = heat F to W1 = heat

The Mark IV/AC control board has a lockout circuit to stop compressor operation if any one of its safety switches opens (high pressure switch and low pressure switch on unit sizes 024 through 060). If the low temperature switch opens, the unit will go into the cooling mode for 60 seconds to defrost any slush in the water-to-refrigerant heat exchanger. After 60 seconds the compressor is locked out. If the condensate sensor detects a filled drain pan, the compressor operation will be suspended only in the cooling mode. The unit is reset by opening and closing the disconnect switch on the main power supply to the unit in the event the unit compressor operation has been suspended due to low temperature (freezestat) switch, high pressure switch, or low pressure switch on unit sizes 048 thru 060. The unit does not have to be reset on a condensate overflow detection.

The Mark IV/AC control circuit fault output sends a signal to an LED on a wall thermostat. Figure 14 shows for which functions the fault output is “on” (sending a signal to the LED).

Figure 14.

LEDs Fault

Indication

Yellow Green Red Output

Normal Mode Off On Off Off High Pressure Fault Off Off Flash On Low Temperature Fault* Flash Off Off On Condensate Overflow On Dim Off On Brownout Off Flash Off On Load Shed Off Off On Off Unoccupied Mode On On Off Off Unit Shutdown Off Flash Off On

*In heating mode only

Unit

Time

Clock

Unit

Chassis Ground

Additional

Units

IM 526 / Page 15

New MicroTech 2000 WSHP Controller Unit

The MicroTech 2000 WSHP unit controller is a preprogrammed, pretested microprocessor which:

● Controls unit heating and cooling functions in response

to a wall mounted comfort sensor.

● Monitors safety controls in each heat pump and

responds accordingly.

● Monitors discharge air temperature and leaving water

temperature at each heat pump.

● Provides fan, reversing valve, and compressor opera-

tion.

● Provides control outputs for boilerless system electric

heat, motorized valves, fresh air damper, and other auxiliary equipment.

● Provides operation status of all vital unit functions.

● Provides optional night setback override for tenant com-

fort.

The MicroTech 2000 WSHP unit controller supports a minimum of 6 analog inputs, 4 digital inputs and 5 digital outputs. All input and output connections to the controller are made using Insulation Displacement Connectors (IDC).

The controller can operate a unit as either a stand-alone device (for start-up, etc.) using factory programmed setpoints (see table below), or preferably, as part of the MicroTech Network System through a MicroTech Communications Gateway (MCG). On a call for constant fan operation, the fan relay is energized. On a call for cooling, the fan is energized (if not already on) and after a time delay the compressor contactor is energized. On a call for heating, the fan is energized (if not already on) along with the reversing valve and after a time delay the compressor contactor is energized.

Standard lockout circuitry causes compressor lockout if any one of its safety switches opens. In addition, when a low temperature fault occurs the unit will run in the cooling mode for 60 seconds to defrost the water to refrigerant heat exchanger coil. If the condensate sensor detects a filled drain pan, the compressor operation will be suspended only in the cooling mode. The unit can be reset by either disconnecting power at the disconnect, feeding power to the

unit or by use of the Monitor™* program through the MicroTech Network System. The unit does not have to be reset on a condensate overflow detection.

A single onboard LED gives indication of the unit status

in relation to the following:

LED on — Occupied LED mostly off — Unoccupied LED mostly on — Unoccupied override LED flashing — Fault

If the unit controller has not been assigned a logical address, the intensity of the LED is low. If a logical address has been assigned, the LED intensity is high.

Additional status and details are available by use of the Monitor™ program and the MicroTech Network system either by direct connection using a portable IBM-compatible computer or through the system computer.

The amount of user control without the use of the network is dependent on the type of comfort sensor used with the unit. The room temperature sensor is currently available in the following configurations:

● With LED indication and tenant override

● With LED indication, tenant override and setpoint differ-

ential adjustment

The LED display indicates the same conditions that the onboard LED does. The tenant override switch allows the tenant to switch from an unoccupied to an occupied comfort setpoint for a preprogrammed period of time. The tenant setpoint differential adjustment allows heating and cooling setpoint differentials to be modified by the tenant.

*The Monitor™ program is sold as part of the MicroTech Network System.

This device complies with part 15 of the FCC Rules.

Operation is subject to the following two conditions:

1. This device must not cause harmful interference.

2. This device must accept any interference received, including interference that may cause undesired operation.

DESCRIPTION FACTORY PROGRAMMED SETPOINT ADJUSTABILITY RANGE

Occupied Heating Setpoint 70°F (21°C) 35°-120°F (1.7°-49°C) ➀➄ Occupied Cooling Setpoint 74°F (23°C) 35°-120°F (1.7°-49°C) ➃➄ Fan - Occupied On On, Cycle, Heat, Cycle/Cool On Unoccupied Heating Setpoint 60°F (16°C) 35°-120°F (1.7°-49°C) ➀ Unoccupied Cooling Setpoint 85°F (29°C) 35°-120°F (1.7°-49°C) ➂ Fan - Unoccupied Cycle On, Cycle Tenant Override - 1st press 1:00 Off, 0:30 - 8:00 Tenant Override - 2nd press Off Off, 0:30 - 8:00 Differential 2°F (1.2°C) 1°-10°F (0.6°-5.6°C) ➄ Auto / Manual Auto Manual (occupied, unoccupied, fan only, off) Next Filter Change (hours) 600 100 - 5000 Clock Schedule 1 Up to 32 Load Shed Start Level Off Off, 1 to 7 Tenant Setpoint Adjustment Off (0°F, 0°C) Off, On (3°F, 1.7°C) Low Temperature Warning 55°F (13°C) 35°F (1.7°C) — high not used High Temperature Warning 95°F (35°C) Low not used — 120°F (49°C)

➀ Unoccupied heating setpoint cannot exceed high warning setpoint. ➁ Occupied heating setpoint cannot exceed unoccupied heating setpoint. ➂ Unoccupied cooling setpoint cannot be lower than low warning setpoint. ➃ Occupied cooling setpoint cannot be lower than unoccupied cooling setpoint. ➄ Occupied heating and occupied cooling setpoints must differ by at least the differential.

NOTICE

Page 16 / IM 526

14-Position Terminal Strip

Pin Designation Description

1CTransformer ground (Ovac) 2RTransformer supply (24vac) 3V-DC power connection 4PPump request output 5AAlarm fault output 6UUnoccupied input 7LLoad shed input 8ERemote shutdown input

9F+DC power connection 10 Y1 Occupied cooling mode input 11 W1 Occupied heating mode input 12 G Fan only input 13 W2 Unoccupied heating mode input 14 O` Tenant override input

Board Status LED’s Fault Output

Mode Yellow Green Red Terminal A

Occupied Off On Off Energized Unoccupied On On Of Energized Load Shed Off Off On Energized Condensate Overflow On Dim Off De-Energized High/Low Pressure Fault Off Off Flash De-Energized Low Temperature Fault* Flash Off Off De-Energized Brownout Off Flash Off De-Energized Emergency Shutdown Off Flash Off De-Energized

*in heating mode only Note: The fault output is energized when no faults exist. The fault ouput is

de-energized during faults and when unit power is off.

The Mark IV/AC control board is provided with three drive terminals, R(24vac), F(24vdc), and C(Ovac) that can be used by the end user to drive the thermostat inputs (G, Y1, W1, and W2) and control inputs (U, L, E, and O). Any combination of a single board drive terminal (R, F, or C) may be used to operate the Mark IV/AC boards control or thermostat inputs. However, only one drive terminal (R, F, or C) can be connected to any individual input terminal or damage will occur. Some of the control inputs are used within the Water Source Heat Pump and not accessible to the end user. For example, HP, LT, and COF are not available for use by the end user.

Typically the Mark IV/AC board’s R(24vac) terminal is used to drive the board’s thermostat inputs and control inputs by connecting it to the R terminal of an industry standard thermostat. The control outputs of the standard thermostat are then connected to the Mark IV/AC board thermostat inputs and control inputs as needed. any remaining board input(s) may be operated by additional thermostat outputs or remote relays (dry contacts only).

All Mark IV/AC board inputs must be operated by dry contacts powered by the control board’s power terminals. No solid state devices (Triacs) may be used to operate Mark IV/AC board inputs. No outside power source may be used to operate Mark IV/AC board inputs.

Using Drive Using Drive Using Drive

Te rminal R (24vac) Terminal F (24vdc) Terminal C (ground)

De-engergized Energized D-energized Energized De-energized Energized

Place the Meters

Red (+) Lead on

Place the Meters Place the Meters Place the Meters

Input to be

on Black (-) Lead Black (-) Lead Black (-) Lead

checked

on C on V on R

U, L, E, Y1, W1, 10 to 22 to

Ovdc

30 to 10 to 22 to

G. W2. P 14vac 26vac 33vdc 14vac 26vac

*Do I need to use the same drive terminal for all Mark IV/AC board inputs?

LED Status and Fault Output Status

General Use and Information

Mark IV/AC Sequence of Operation

Yes

Read Outputs

Check Timers

Pres. Sw ?

Brown Out ?

Low Temp Sw ?

Lo Shed ?

N S B ?

Cond. Overflow?

R - W 1 ?

R -Y 1 ?

Stop Comp.

Flash Red LED

Stop Comp.

Stop Fan

Flash Green LED

Stop Comp.

Htg Mode?

Yes

Flash Yellow L ED

Stop Comp.

Turn On Red LED

R - W 2 ?

Yes

Start Comp.

Cooling Mode

Turn On Yellow LED

Stop Comp.

Reversing Valve On

Time Delay

Start Comp.

IM 526 / Page 17

Thermostat Connection Diagrams

Mark IV/AC Units – Unit Sizes 007-060

Deluxe Automatic Changeover Thermostat (P/N 105571001)

Standard Automatic & Manual Changeover Thermostat (P/N 105570701)

Non-Programmable Electronic Thermostat (P/N 105570801)

P/N 106069001 Includes Thermostat and Subbase (Honeywell P/N T834C2416) Fan Switch: Auto / On System Switch: Heat / Off / Cool

P/N 105570701 Includes Thermostat and Subbase (Honeywell P/N’s T874A1598 and Q674E1460) Fan Switch: Auto / On System Switch: Off / Heat / Auto / Cool

P/N 105571003 Includes Thermostat and Subbase (Honeywell P/N’s T874C1869 and Q674C1579) Fan Switch: Auto / On / Tenant Override System Switch: Off / Auto

Note: Thermostat provides a fixed 13°F differential between W1 and W2.

Operation: The units Mark IV/AC board will be in the occupied mode, monitoring terminals W1 and Y1 and ignoring terminal W2, when the time clock contacts are open. The Mark IV/AC board will be in the unoccupied mode, monitoring terminal W2 and ignoring terminals W1 and Y1, when the time clock contacts are closed. No cooling is allowed during the unoccupied mode. The tenant override feature of the thermostat allows the occupant to force a 2-hour override of unoccupied mode. During this override period the W1 and Y1 terminals are monitored and the W2 terminal is ignored (same as occupied).

P/N 105570801 Includes Thermostat and Wall Plate (Honeywell P/N T8524D1064)

Manual Changeover Thermostat (P/N 106069001)

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GWY R

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GW1Y1 A Rc Rh

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

OW2GW1Y1 A R

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

Time Clock (by others)

Daisy-chain connection to additional units Mark IV/AC board “U” terminals

OW2GW1Y1 F E L U A P V R C

GW1Y1 RRc C

Thermostat Terminals

Page 18 / IM 526

Non-Programmable Electronic Thermostat (P/N 105570801)

Programmable Electronic Thermostat (P/N 105570901)

P/N 105570901 Includes Thermostat and Wall Plate (Honeywell P/N T8524D2111)

P/N 105571003 Includes Thermostat and Subbase (Honeywell P/N’s T874C1869 and Q674C1579) Fan Switch: Auto / On / Tenant Override System Switch: Off / Auto

Note: Thermostat provides a fixed 13°F differential between W1 and W3.

Unit Sizes 070-120

Deluxe Automatic Changeover Thermostat (P/N 105571001)

P/N 105570801 Includes Thermostat and Wall Plate (Honeywell P/N T8524D1064)

P/N 105570901 Includes Thermostat and Wall Plate (Honeywell P/N T8624D2111)

WSHP Mark IV/AC Board Low Voltage Terminal

OW2GW1Y1 F E L U A P V R C

GW1Y1 RRc C

Thermostat Terminals

WSHP Circuit 1 Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1F E L U A P V R C

OW3GW1Y1 W2 A R

Thermostat Terminals

WSHP Circuit 1 Mark IV/AC Board Low Voltage Terminal Strip

WSHP Circuit 2 Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1F E L U A P V R C

Daisy-chain connection to additional units Mark IV/AC board “U” terminals

WSHP Circuit 2 Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C OW2 G W1 Y1 F E L U A P V R C

Time Clock (by others)

GW1Y1W2Y2RRcC

Thermostat Terminals

WSHP Circuit 1 Mark IV/AC Board Low Voltage Terminal Strip

WSHP Circuit 2 Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C OW2 G W1 Y1 F E L U A P V R C

GW1Y1W2Y2RRcC

Thermostat Terminals

IM 526 / Page 19

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

Options on Mark IV/AC Units

The auxiliary relay is designed to interface external equipment with the Mark IV/AC board. The auxiliary relay has been provided with the components necessary to protect from electrical damage that may occur to the Mark IV/AC board when using standard off-the-self relays. The auxiliary relay can be used to provide fault signals, unit operation signals, or to provide a means for remote equipment to control the Mark IV/AC board. The orange, yellow, and white connections are short flying leads pre-attached to the board. The diagrams shown are some connection examples.

Auxiliary Relay (P/N 106059701)

This multiple unit control board is an accessory used when you need to control up to 3-units from a single thermostat. The board is typically mounted in the unit control box closest to the thermostat. A maximum of 2 boards may be used together if up to 6-units must be connected and controlled from a single thermostat.

This version of the board uses VAC relays and should not be used in combination with any other accessories or equipment that require VDC connections to the “G”, “W1”, or “Y1” terminals (i.e. Boilerless System Kit).

The multiple unit control board provides the components necessary to protect the Mark IV/AC board from electrical damage that may occur when using standard off-the-self relays.

Do not use the unoccupied (U-terminal) feature with the multiple unit control board.

Multiple Unit Control (up to 3 units) (P/N 056794201)

Multiple Unit Control (up to 2 units) (P/N 106059801)

This multiple unit control board is an accessory used when you need to control up to 2-units from a single thermostat. The board is typically mounted in the unit control box closest to the thermostat. The

“

G”, “W”, “Y”, “C”, and “L” connections are short flying leads pre-attached to the board. A maximum of 3 boards may be used together if up to 4-units must be connected and controlled from a single thermostat.

This version of the board uses VDC relays and should not be used in combination with any other accessories or equipment that require VAC connections to the “G”, “W1”, or “Y1” terminals (i.e. Boilerless System Kit). Do not use the unoccupied (U-terminal) feature with the multiple unit control board.

The multiple unit control board provides the components necessary to protect the Mark IV/AC board from electrical damage that may occur when using standard off-the-self relays.

Operation: In this example the auxiliary relay contacts can be used to indicate a fault condition. With the auxiliary relay connected as shown, the normally open contacts will close during a fault condition.

Operation: In this example the auxiliary relay contacts can be used to signal WSHP fan operation to another device. In this example when the thermostat energizes the “G” terminal the auxiliary relay normallyopen contacts wil close.

Operation: In this example the auxiliary relay is used to interface other control devices to the Mark IV/AC board. Using the Orange (-) and White (+) wires, and 24vac or 24vdc, another device could be used to start and stop the WSHP heating sequence.

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

TB3

TB2

TB1

Multiple Unit

Control Panel

TB4

GWY R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GW1Y1 R Rc C

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

Multiple Unit

Control

Panel

GWY CL

GW1Y1 R Rc C

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Page 20 / IM 526

Motorized Valve & Relay for Unit Sizes 007 thru 060

Motorized Valve & Relay for Unit Sizes 070 Thru 120

Typical Motorized Valve Installation

Wired as shown below the motorized valve will open on a call for compressor operation. These 1-

⁄4" valves are power-open power-close. Valve and auxiliary relay are purchased separately.

Note: The wiring shown below can only be used when the “P” terminal is not being used as a pump restart signal to other equipment. If the “P” terminal must be used as a pump restart signal to other equipment, then wire the auxiliary relay’s yellow wire to “Y1”, white wire to “W1”, and orange wire to “C”, then the valve will open on a call for occupied heating or cooling from the thermostat.

Wired as shown below the motorized valve will open on a call for compressor operation. Valves for unit sizes 007 to 019 are

⁄2"

power-open spring-return while unit sizes 024 to 060 are

⁄4" power-open power-close. Other thermostat combinations may be used. Valve and auxiliary relay are purchased separately.

P/N 105571003 Includes Thermostat and Subbase (Honeywell P/N’s T874C1869 and Q674C1579) Fan Switch: Auto / On / Tenant Override

Note: Thermostat provides a fixed 13°F differential between W1 and W2.

P/N 105571003 Includes Thermostat and Subbase (Honeywell P/N’s T874C1869 and Q674C1579) Fan Switch: Auto / On / Tenant Override System Switch: Off / Auto

Note: Thermostat provides a fixed 13°F differential between W1 and W2.

P/N 060977401 - 1/2" Motorized Valve Kit P/N 060977301 - 3/4" Motorized Valve Kit P/N 059004354 - Valve Relay Kit

P/N 061201202 - 1/2" Valve Relay Kit P/N 061201002 - 1-1/4" Motorized Valve

Note: Wire motorized valve relay to circuit one (1) on all dual circuit machines sizes 070-120, as illustrated above.

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2G W1Y1 F E L U A P V R C

Connector

Valv e

Anti-Short Bushing

36" (915 mm)

Lead Length

Time Clock (by others)

Conduit

Pins,

Female

Black to 6

Blue to 3

White to 1

3 1

Plug

Orange

Yellow

White

Auxiliary Relay

OW2G W1Y1 A R

Thermostat Terminals

631

Orange

Auxiliary Relay

Spade Terminal

(On Circuit 1

Yellow

White

COMMON

Mark IV/AC

45231

Valve

COMP Spade

Terminal (On

Circuit 1 Mark

IV/AC Board)

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit1)

OW2GW1Y1 F E L U A P V R C

OW2GW1Y1 A R

Thermostat Terminals

Compressor

Contactor

(Circuit 1)

Daisy-chain to additional Mark IV/AC board “U” terminals

11/4" or 11/2" Valve

66" (1676 mm)

Lead Length

Conduit

Anti-Short Bushing

Time Clock (by others)

Daisy-chain to additional Mark IV/AC board “U” terminals

Plug

Black to 1

Red to 2

2 3

White to 3

4 5

Yellow to 4 Orange to 5

Pin, Male

To Low Voltage

Hole on Unit

Return Water Connection

Flexible Hose

Motorized Valve Assembly

Conduit Assembly

To Main System

Shutoff Valve

Boilerless System Kit (BSK)

P/N 0062522201 for Sizes 007 Thru 042 P/N 0062522204 for Sizes 048 Thru 060

IM 526 / Page 21

The BSK option for use with the Mark IV/AC control board provides the capability to control a remote duct heater. The duct heater must be provided with a low voltage control circuit that only requires a set of dry contacts for operation.

The contacts shown on the Boilerless System board (terminals 1, 2, and 3) are used to control the remote duct heater, the N.O. contacts will close on a call for duct heater heat. POT1 provides a means to manually adjust the water temperature setpoint (adjustment range is 43°F to 60°F). The Normal/Override switch provides a means to manually force electric heat to always be used in place of heat pump heat when in the override position (default position is normal heat pump heat).

When the water temperature drops below the value of POT1, then the duct heater will be used instead of heat pump heat on a call for heat from the low voltage thermostat (not included).

The BSK field installed kits include the sheet metal enclosure with cover, wire harness, boilerless system board, auxiliary relay, and water temperature sensor. When used, one BSK is required for each unit. To use the BSK kit you attach the sheet metal enclosure to the unit as shown, route the 4wire harness through knockouts and connect to the Mark IV/AC board, mount and connect and insulate the water temperature sensor on the water supply line, and then connect the duct heater control contacts to the duct heater control circuit.

If night setback (U-terminal) is used, the duct heater will respond to the occupied W1 thermostat signal. The load shed input (L-terminal) cannot be used for other control functions when being used with the BSK. The BSK is a DC voltage device, when the BSK is used the thermostat must be wired for VDC operation, one example is provided below. This example is for a 2-circuit WSHP, R1 is a field supplied 24vdc relay. R1 is not required on 1-circuit units.

Thermostat Terminals

Wire ends

from Boilerlless

System Kit

WSHP Circuit 1 Mark

IV/AC Board Low Voltage

Te rminal Strip

WSHP Circuit 2 Mark IV/AC Board

Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C OW2 G W1 Y1 F E L U A P V R C

GW1Y1W2Y2RRcC

OR BR

43 Ohm

Wire Ends to be Field

Connected to the

Mark IV/AC Board

43 Ohm

WSHP Mark IV/AC Board Low Voltage Terminal Strip

GR GR

Orange

Yellow

White

4-pin

Plug

Auxiliary Relay

Water

Temperature

12345

Sensor

Signal to remote duct heater control circuit

Boilerless

System

Board

Normal

Pot 1

Override

Page 22 / IM 526

Pump Restart Relay Kit P/N 061419001

Used as an option with the Mark IV/AC board, the pump restart relay kit provides a means to alert the loop water controller that water flow is required by a WSHP so that the system pump can be started. This option is typically used in installations where the pump may be shut off when there is no need for water flow (i.e. temperature OK, etc.). Typically only one pump restart relay kit is required per installation as up to 200 Mark IV/AC boards can be “daisy-chained” together.

The Mark IV/AC “P” terminal is used to determine WSHP compressor operation. Wired as shown below, when compressor operation is required, the Mark IV/AC “P” terminal

will change state causing a contact closure between terminal 58 and 64 signaling the loop water control (LWC) panel to restart the loop pump if Off.

The pump restart relay kit is typically mounted within one WSHP or within the LWC panel, whichever is more convenient, diagrams are provided below for each location. To install the relay, remove the cover on the double-faced tape provided on the relay and attach the relay either to the inside of the LWC panel (adjacent to circuit breaker CB1 and terminal block TB3) or in the WSHP control box (in a convenient location), then wire as shown below.

WSHP Mark IV/AC Board Low Voltage Terminal Strip

Pump

Restart

Relay

OW2GW1Y1 F E L U A P V R C

Loop

Water Controller Terminals

Daisy chain to other Mark IV/AC board “P” and “C” terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit 1)

Pump

Restart

Relay

OW2GW1Y1 F E L U A P V R C

Loop

Water Controller Terminals

Daisy chain to other Mark IV/AC board “P” and “C” terminals

Wiring Pump Restart Relay when Installed within the LWC Panel

Wiring Pump Restart Relay when Installed within a WSHP Control Box

IM 526 / Page 23

Field Installed Options on MicroTech 2000 Units

MicroTech 2000 units can provide up to 4-outputs, that can be configured for any of the following output control signals:

1) Scheduled Output When using a Network Master Panel (NMP) these outputs can be assigned to one of 32 available schedules. The output will energize when the assigned schedule is occupied and de-energize when in unoccupied. These outputs could be used to control lights, etc.

2) Auxiliary Heat (Skin Heat) When using a Loop Water Controller (LWC) the MicroTech 2000 receives loop water temperature information from the LWC and will use the Auxiliary Heat output for heating when loop water temperature is inappropriate for heat pump heating. These outputs provide a signal that can be used to control a remote electric heater. The output will energize on a call for electric heat and de-energize when not required.

3) Fresh Air Damper These outputs provide a signal that can be used to control a remote fresh air damper. The output will energize when the unit fan is energized and de-energize when the unit fan is de-energized.

4) Motorized Water Valve These outputs provide control for a motorized water valve that can be used to stop or divert flow away from the WSHP when compressor operation is not needed. The output will be energized when compressor operation is required.

If more than one of the above control signals is required on a single WSHP, the MicroTech 2000 Auxiliary board (073312701) must be used and these additional output control signals will be connected to the Auxiliary board. The Auxiliary board is provided in all 2-circuit units. 1-circuit units can provide up to 4-outputs while 2-circuit units only have 3-outputs available. The 4th control signal output shown in the diagrams below is not available on 2-circuit units.

If the Auxiliary board is added in the field to provide additional outputs it will need to be mounted within the WSHP control box so that J1 on the Auxiliary board can be connected to J6 on the MicroTech 2000 board without exceeding a maximum wire length of 10˝.

Also, each output is by default configured to “none” and must be field set to one of the four signal types listed above using the Monitor software, cable, and a PC communicating to the unit through an MCG panel.

1st Control Signal Output

2nd Control Signal Output

3rd Control Signal Output

4th Control Signal Output

Terminal Boards

(Located externally on the WSHP chassis)

24VAC

Pilot Duty Relay

(by others)

Terminals Located on

Microtech 2000 Auxiliary Board

24VAC

Pilot Duty Relay

(by others)

Use contacts as needed for option

Terminals Located on

Microtech 2000 Auxiliary Board

24VAC

Pilot Duty Relay

(by others)

Use contacts as needed for option

Terminals Located on

Microtech 2000 Auxiliary Board

J10

24VAC

Pilot Duty Relay

(by others)

Use contacts as needed for option

1 234567

ELUPC

4 321

(by others)

24VAC

4 321

(by others)

24VAC

4321

(by others)

24VAC

Troubleshooting Water Source Heat Pump

Page 24 / IM 526

Low Voltage, check power supply voltage

Check wiring - loose or broken and check for bad connection

Check relays and contacts, also capacitor and wiring

Check high pressure switch and low temperature switch to see if unit is cycling on the safety

Check to see if the reversing valve is not hung up and is operating correctly

Check condensate overflow switch in cool mode of operation

Fuse may be blown, circuit breaker is open

Fan, nor Compressor Run

Compressor runs in short cycle

Compressor attempts to start but doesn’t

Wires may be loose or broken. Replace or retighten wires

Fan operates,

Unit

Insufficient cooling or heating

Compressor does not

Unit Control, check thermostat for correct wiring or bad t’stat

Check capacitor

Check wiring - loose or broken and check for bad connection

Hi pressure lockout A. Cool mode, check water flow B. Heating mode, check air flow C. Check reversing valve for proper valve position

Check compressor overload make sure it’s closed

Check compressor to ground, or for internal short to ground.

Compressor winding may be open. Check continuity with ohm meter

Check compressor wiring for defective wiring or loose connection

Check for defective compressor internal windings with ohm meter

Check for bad compressor capacitor

Check for lock rotor amp draw

Check themostat for improper location

Check for proper air flow. Filter could be dirty

Check blower assembly for dirt or bad fan motor capacity

Check for low refrigerant charge

Check amp draw on blower assembly

Maintenance

1. Normal maintenance on all conditioners is generally limited to filter changes. Motors used with WSHP unit size 007 through 060 are provided with permanently lubricated motors and require no oiling even though oil caps may be provided. Larger sizes 070, 090 and 120 with caps should be oiled in accordance with the oil label on each heat pump.

2. Filter changes are required at regular intervals. The time period between changes will depend upon the project requirements. Some applications such as motels produce a lot of lint from carpeting and linen changes, and will require more frequent filter changes. It is suggested that the filter be checked at 60-day intervals for the first year until experience is acquired. If light cannot be seen through the filter when held up to sunlight or a bright light, it should be changed. A more critical standard may be desirable.

3. The condensate drain pan should be checked annually and cleaned and flushed as required.

4. Recording of performance measurements of volts, amps, and water temperature differences (both heating and cooling) is recommended. A comparison of logged data with start-up and other annual data is useful as an indicator of general equipment condition.

5. Periodic lockouts almost always are caused by air or water problems. The lockout (shutdown) of the conditioner is a normal protective result. Check for dirt in the water system, water flow rates, water temperatures, airflow rates (may be dirty filter), and air temperatures. If the lockout occurs in the morning following a return from night setback, entering air below machine limits may be the cause.

IM 526 / Page 25

Page 26 / IM 526 IM 526 / Page 26

Product Warranty

Optional Warranties

McQuay International, herein referred to as the “Company,” warrants to the original owner that each water-to-air heat pump is free from defects in material and workmanship. Any part or portion thereof (except air filters if of the throwaway type) which becomes defective under normal use during the period of this warranty will be repaired or replaced provided the Company’s examination shall prove to its satisfaction that the part was or became defective under normal use. This warranty contemplates that first year maintenance labor was arranged for with the installer or otherwise at the time the conditioner was purchased or installed. The Company’s obligations under this warranty are limited to: (a) repairing the defective part or (b) furnishing a replacement part provided the defective part is returned to the factory, transportation charges prepaid. No reimbursement will be made for expenses incurred in making field adjustments or replacements unless specifically authorized in writing by the Company.

To obtain assistance under the parts warranty or extend-

ed motor-compressor warranty, simply contact the selling agency. To obtain information or to gain factory help, contact McQuay International, Warranty Claims Department, P. O. Box 1551, 13600 Industrial Park Blvd., Minneapolis, MN 55440; telephone (612) 553-5330.

This warranty constitutes the buyer’s sole remedy. It

is given in lieu of all other warranties. There is no implied warranty of merchantability or fitness for a particular purpose. In no event and under no circumstance shall the company be liable for incidental or consequential damages, whether the theory be breach of this or any other warranty, negligence, or strict tort.

No person (including any agent, salesman, dealer or dis-

tributor) has authority to expand the Company’s obligation beyond the terms of this express warranty, or to state that the performance of the product is other than that published by the Company.

One-Year Warranty On Entire Conditioner

One-Year Refrigeration Circuit Warranty

Hermetically sealed motor-compressor assemblies and all components of refrigeration circuits not readily separable therefrom are warranted to the original owner for one year. Refrigerating circuits consist of the motor-compressor assembly, evaporator coil, condenser coil, and interconnecting tubing. Repairs under this warranty will be made at the Company’s expense provided that the refrigerating circuit is delivered, without shipping damage, transportation prepaid, to the factory or to a factory designated repair station, at the Company’s option. This one-year warranty does not include any other parts of the equipment such as filters,

fans, fan motors, control, cabinet parts, electric relays, capacitors, protective devices, or wiring. The Company is not obligated under this warranty for field labor such as service for inspection, removing, packing and/or reinstalling the refrigeration circuit, nor for return transportation charges.

If the hermetically sealed circuit contains a defect at

the time of initial start-up that requires delivery of the conditioner to the Company or a factory designated repair station, the contractor perferning this fixed allowance.

General Conditions

The above warranties are void if the Company’s equipment has been damaged, misused, subjected to abnormal use or service or if its serial number has been altered, defaced or removed, or payment for the equipment is in default. The Company is not responsible for service to correct conditions due to misapplication, improper installation, inadequate wiring, incorrect voltage conditions or unauthorized opening of the refrigeration circuit, operation at abnormal temperatures and water flow rates, operation on an open condenser water circuit, nor for consequential damages. In

case the Company’s equipment is installed in conjunction with cabinets, grilles, louvers, controls or other parts manufactured by others, these warranties shall apply only to the Company manufactured portion of the equipment. The conditions of the warranty plan are effective for eighteen (18) months from date of factory shipment. The Company reserves the right to make a handling and inspection charge in the case of parts or equipment improperly returned as defective and/or as being in warranty.

2nd to 5th year refrigerant circuit warranty

Hermetically sealed motor-compressor assemblies and all components or refrigerating circuits not readily separable therefrom are warranted to the original owner for use for four additional years. Refrigerating circuits consist of the motor-compressor assembly, evaporator coil, condenser coil and interconnecting tubing. Repairs under this warranty will be made at the Company’s expense provided that the refrigerating circuit is delivered, without shipping damage,

prepaid, to the factory or to a factory designated repair station, at the Company’s option. This warranty does not include any other parts of the equipment such as filters, fans, fan motors, controls, cabinet parts, electrical relays, capacitors, protective devices, or wiring. The Company is not obligated under this warranty for field labor such as service for inspection, removing, packing and/or reinstalling the refrigeration circuit, nor for return transportation charges.

IM 526 / Page 27

The conditions of this warranty plan are effective for sixty-six (66) months from date of factory shipment. The Company reserves the right to make a handling and inspection charge in the case of parts or equipment improperly returned as defective and/or as being in warranty.

Optional 2nd to 5th year compressor warranty

The hermetically sealed motor-compressor is warranted to the original owner for four (4) additional years. Compressors under this warranty will be supplied at the Company’s expense provided the failed compressor is returned, trans-

portation prepaid, to the factory. This warranty does not include any other parts of the equipment such as fans, fan motors, controls, cabinet parts, electrical relays, capacitors, protective devices, or wiring. The Company is not obligated under this warranty for field labor such as service for inspection, removing, packing and/or reinstalling the refrigeration circuit, nor the return transportation charges.

This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.mcquay.com

McQuay CMU Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual