McQuay FCV007 Installation Manual

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Vertical Water Source Heat Pumps

Unit Sizes 007 – 012 / R-22 Refrigerant Unit Sizes 019 – 060 / R-410A Refrigerant

Contents

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cleaning & Flushing System . . . . . . . . . . . . . . . . . . . . 6

Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ty pical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 9-11

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

Thermostat Connections. . . . . . . . . . . . . . . . . . . . 16-17

Options for Mark IV/AC Units . . . . . . . . . . . . . . . . 18-19

Field Installed Options on MicroTech Units . . . . . . . . 20

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . 21

Troubleshooting WSHP. . . . . . . . . . . . . . . . . . . . . 22-23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting Refrigeration Circuit . . . . . . . . . . . . . 24

Installation & Maintenance Data

Group: WSHP

Part Number: 106751101

Date: November 2003

IM 778

Page 2 / IM 778

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, do not operate this equipment 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. Before installation, check the available closet dimensions versus the dimensions of the unit.

5. 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.

6. The installing contractor will find it beneficial to confer with piping, sheet metal, and electrical foremen before installing any conditioners.

7. 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.

Model Nomenclature

Product Category

W = WSHP

Product Identifier

FCV = Floor Mounted/Standard Range FCW = Floor Mounted/Geothermal

Design Series

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

Nominal Capacity

007 = 7,000 009 = 9,000 012 = 12,000 019 = 19,000 024 = 24,000 030 = 30,000 036 = 36,000 042 = 42,000 048 = 48,000 060 = 60,000

W FCV 1 009 M E Y L T

Discharge Air

T = Top

Return Air

L = Left R = Right

Future

(None)

Voltage

A = 115/60/1 E=208-230/60/1 F=208-230/60-/3 J=277-265/60/1 K=460/60/3 L= 575/60/3

50 Hz

M=230/50/1 N = 380/50/3

Note: For illustration purposes only. Not all options available with all models.

Please consult McQuay Sales Representative for specific availability.

Controls

M = Mark IV L = Microtech 2000 A = BACnet

CAUTION

Note: Installation and maintenance must be performed only by qualified personnel who are familiar with local codes and regulations, and are experienced with this type of equipment.

Sharp edges can cause personal injury. Avoid contact with them.

IM 778 / Page 3

Unit location

1. Locate the unit in an area that allows for easy removal of the filter and access panels, and has 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 access has been provided including clearance for duct collars and fittings at water and electrical connections.

3. Allow adequate room around the unit for a condensate trap.

4. The unit can be installed “free standing” in an equipment room; however, closet installations are more common for small vertical type units. Generally, the unit is located in the corner of a closet with the non-ducted return air facing 90° to the door and the major access panels facing the door as in Figure 1. Alternatively, the unit can have a ducted return air with the opening facing the door and the major access panels facing 90° to the door as in Figure 2.

5. It is recommended that the unit be located on top of a vibration absorbing material such as rubber or carpet to reduce any vibration. See Figure 8, page 6.

6. If optional field installed controls are required (boilerless system), space must be provided for the enclosure to mount around the corner from the electrical entrances. Do not locate the side of the unit too close to a wall. See Figures 1 and 2.

Minimum distance requirement from return air duct collar to wall, for non-ducted units.

Model Distance

007 – 012 4 inches 019 – 024 5 inches 030 – 036 6 inches 042 – 048 8 inches

Filter access

Each unit is shipped with a filter bracket for side filter removal.

Heat Pump with

Left-Hand Return Air

Arrangement

Heat Pump with

Right-Hand

Return Air

Arrangement

Heat Pump with

Left-Hand Return Air

Arrangement

Heat Pump with

Right-Hand

Return Air

Arrangement

Return

Air

Opt. Controls

Elec. Entrance

Main Access Panel

Return

Air

Opt. Controls

Elec. Entrance

Main Access Panel

Condensate

Water Supply

Water Return

Condensate

Water Supply

Water Return

Return Air Thru Louvered Door

Risers

Return Air Thru Louvered Door

Return

Air

Duct &

Grille

Opt. Controls

Elec. Entrance

Main Access Panel

Opt. Controls

Elec. Entrance

Main Access Panel

Condensate

Water Supply

Water Return

Condensate

Water Supply

Water Return

Risers

Return

Air

Duct &

Grille

NOTE: Minimum distance requirement for non-ducted units. (see chart above).

Figure 1. Typical closet installation with louver door return

Figure 2. Typical closet installation with ducted return

Page 4 / IM 778

Ductwork and attenuation

Discharge ductwork is normally used with these conditioners. Return air ductwork may also be required, but will require field installation of a return air duct collar/2" (51mm) filter rack kit.

All ductwork should conform to industry standards of good practice as described in ASHRAE Systems Guide.

The discharge duct system will normally consist of a flexible connector at the unit, a non-insulated transition piece to the full duct size, a short run of duct, an elbow without vanes, and a trunk duct teeing into a branch circuit with discharge diffusers as shown in Figure 3. The transition piece must not have an angle greater 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 insulation for sound attenuation. Glass fiber duct board material is more absorbing and may permit omission of the flexible connector.

The ductwork should be laid out so that there is no line of sight between the conditioner discharge and the distribution diffusers.

Return air ducts can be brought in through a wall grille and then to the unit. The return duct system will normally consist of a flexible connector at the unit and a trunk duct to the return air grille. With metal duct material, the return air duct should be internally lined with acoustic insulation for sound attenuation. Glass fiber duct board material is more absorbing and may permit omission of the flexible connector.

Return air ductwork to the unit requires the optional return air duct collar/2" (51mm) filter rack kit. See Figure 4 and 5. The kit can be installed for face side or bottom filter removal. The flexible connector can then be attached to the 1" (25mm) duct collar.

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 puncture the drain pan or the air coil.

Ventilation air

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

The ventilation air system is generally a separate building subsystem with distribution ductwork. Introduce outside air into each return air plenum chamber reasonably close to the conditioner air inlet. 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 8.

Square Elbow (Both Sides Internally Lined With Acoustic Insulation)

Trunk Duct

2 ft. x 2 ft. Diffuser

Discharge Collar

Heat Pump

Duct

Transition

Branch Duct (Internally Lined)

Figure 3.

Figure 4. Sizes 007 thru 048 Optional 2” Return Air Duct Collar Filter Rack

Figure 5. Size 060 Optional 2” Return Air Duct Collar Filter Rack

IM 778 / Page 5

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.

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. For 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 also can 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 Figures 8, 9, and 10 for typical piping setup.

4. Some flexible hose threaded fittings are supplied with sealant compound. If not, apply Teflon tape for 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. Do not connect any unit 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. Condensate piping can be steel, copper or PVC. Each unit includes a condensate connection.

8. Units are internally trapped.

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 affected by external static pressure.

Figure 6. Sizes 007 through 012

Figure 7. Sizes 019 through 060

FAN

MOTOR

FAN

MOTOR

WHITE (COMMON) BROWN (CAPACITOR) BLUE (HIGH SPEED) SIZE 007, 009, 012

RED (LOW SPEED)

WHITE (COMMON) BROWN (CAPACITOR) BLACK (HIGH SPEED) SIZES 024, 030,

036, 042, 060 RED (LOW SPEED)

SIZES - 019, 048

Page 6 / IM 778

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

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

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

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

Figure 8. Typical Vertical Unit Piping

Ball Valve with Y-Strainer

Isolator Pad

Flexible Return Hose with

Swivel Fittings

Condensate Drain

Supply Air

Flexible Duct Collar

Two 90° Turns (Ductwork Sized Based on Airflow)

Accoustical Thermal Duct Lining (10’)

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 blow-down, 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 over-torque 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.

Return Air

Flexible Supply Hose with

Swivel Fittings

Ball Valve with Mesurflo

Line Voltage Disconnect

Blower Motor Access

IM 778 / Page 7

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 pre-lubricated 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 should be employed to continuously re-move 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.

Page 8 / IM 778

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 FCV

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 FCW

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 25°F (-4°C), with both air and water at flow rates used in the ARI Standard 330-86 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 limits

Water limits

Extended Range

Standard Units

Units

Cooling Heating Cooling Heating

Min. Ent. Water ➀ ➁ 55°F/13°C 55°F/13°C 30°F/-1°C 20°F/-6°C Normal Ent. Water 85°F/29˚C 70˚F/21°C 77°F/25˚C 40˚F/5°C Max. Ent. Water 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 under voltage for extended periods of time will experience premature component failure. Three phase system unbalance should not exceed 2%.

IM 778 / Page 9

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.

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 ter-

minals (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.

Figure 10. Typical Mark IV/AC wiring diagram

COMPONENT LAYOUT

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

CC - Compressor Contactor HTR - Crankcase Heater (Optional) CAP - Motor Capacitor

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

L1 L2

Compr

Motor

Heater

Fan

Motor

Ground

Lo Temp

Hi Pressure

Lo Pressure

Reversing Valve Solenoid

Condensate

Sensor

UAP

Fan

Common

W1Y

Compressor

Mark IV

Board

Page 10 / IM 778

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)

Figure 11. 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 778 / Page 11

Figure 12. Typical BACnet

WSHP unit controller

Notes:

BACnet

Controller

Page 12 / IM 778

Unit Operation

Three types of units are available: Mark IV/AC control units or units equipped with a MicroTech™ 2000 or BACnet

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 (see Figure 14).

Figure 14.

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 19.

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.

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 13 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 equipment protection switches opens (high pressure switch and low pressure switch). 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. 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 13 shows for which functions the fault output is “on” (sending a signal to the LED).

Figure 13.

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

Clock

Time

Unit

Chassis Ground

Additional

Units

Each McQuay Enfinity vertical water source heat pump can be equipped with a MicroTech 2000 water source heat pump unit controller. The controller is microprocessor-based and is designed to communicate over a LonWorks communications network. The unit controller is factory programmed and tested with all the logic required to monitor and control the unit. The controller sets the unit mode of operation, monitors water and air temperatures, and can communicate fault conditions to a LonWorks communications network.

The MicroTech 2000 unit controllers include unit-mounted return air, discharge air and leaving water temperature sensors. Options include a tenant setpoint adjustment knob and tenant override button, and the capability of substituting the return air sensor with a wall-mounted room sensor.

Each unit controller orchestrates the following unit operations:

● Enable heating and cooling to maintain setpoint based on

a room sensor.

● Enable fan and compressor operation.

● Monitor all safety controls.

● Monitor discharge air temperature.

● Monitor leaving water temperature.

● Relay status of all vital unit functions.

● Support optional control outputs.

IM 778 / Page 13

MicroTech™ 2000 WSHP Unit Controller

Figure 16. MicroTech 2000 Unit Controller LED Indication

Status LED State Mode

On Continually Occupied, Occupied Load

Shed On 1⁄2 sec., Off 5 1⁄2 sec. Unoccupied On 5 1⁄2 sec., Off 1⁄2 sec. Tenant Override, Override

Load Shed Flashing Alarm Condition

An amber, on-board status LED aids in diagnostics by indicating the water source heat pump operating mode and alarm conditions. If there are no current alarm conditions, the LED will indicate the unit operating mode as shown in the table below. If there are one or more alarm conditions present, the LED will flash to indicate an alarm condition.

MicroTech 2000 heat pumps are designed to be linked with a centralized building automation system through a LonWorks communications network for centralized scheduling and management of multiple heat pumps. Wall-mounted room sensors are available to control the heating and cooling operation of each MicroTech 2000 Water Source Heat Pump Unit Controller. A vailable room sensors include: room sensor with LED status and tenant override button, room sensor with LED status, timed-override button, and bi-metal thermostat, room sensor with LED status, timed-override button, and setpoint adjustment, and room sensor with LED status, timed-override button, setpoint adjustment and bimetal thermostat.

Figure 15. MicroTech 2000

™

WSHP unit controller

Figure 17. MicroTech 2000™WSHP unit control box

Page 14 / IM 778

McQuay Enfinity vertical water source heat pumps are available with a factory mounted and tested Alerton BACnet unit controller as a special. The unit controller is factory programmed and tested with all the logic required to control the unit, and is designed to communicate over a BACnet MS/TP communications network to an Alerton BACtalk building automation system (BAS). The controller operates the compressor, fan, and reversing valve as required to maintain the space temperature within the current setpoints. Data regarding equipment status, water and air temperatures, and fault conditions can be monitored by an Alerton BACtalk BAS. Setpoints and other system preferences may be changed remotely using an Alerton BACtalk workstation or Alerton service tool software.

The controller makes operational data and commands available on the Alerton BACtalk network using BACnet objects and properties. Each heat pump controller connects to the BACtalk network using a BACnet MS/TP LAN, which is a simple twisted-pair communications connection that operates at up to 76.8 Kbps. DIP switches on the controller enable the MS/TP MAC address to be set in the range 0-

127. A status LED on the unit indicates communication activity on the MS/TP LAN.

Each BACnet-compliant unit includes discharge air and leaving water temperature sensors, as well as all safety sensors, signals, and switches. Wall-mounted room sensors are available from Alerton to control heating and cooling operation. Available sensors include tamper-resistant stainless steel wall sensors with optional push-button for status override; wall-mounted sensors with tenant setpoint adjustment lever and timed-override button; wall-mounted sensors with LED status, timed-override button, tenant setpoint adjustment buttons, password-protected field service access to operational data, and optional humidity sensor; and wall-mounted sensors with LCD and programmable operation.

Figure 18. BACnet

WSHP unit controller

Each BACnet-compliant controller has the following operating features:

● Start-up – The unit will not operate until all the inputs

and safety controls are checked for normal conditions.

● Fan operation – Fan operation can be customized in

software to run continuously during occupied mode, or to cycle ON or OFF appropriately on a call for heating and cooling.

● Cooling mode – On a call for cooling, the compressor

and fan start immediately. Compressor run-time is calculated as a percent of full cycle time (17 minutes) using proportional-integral control to maximize efficiency.

● Heating mode – On a call for heating, the compressor

and fan start immediately, and compressor run-time is calculated as a percent of full cycle time (17 minutes) using proportional-integral control to maximize efficiency.

● Short Cycle Protection and Random Start – A start

delay of 180 seconds plus the compressor’s MAC address in seconds prevents short-cycling and simultaneous start-up. A minimum 2-minute on time and 5minute off time for the compressor further ensures shortcycle protection.

● Occupied Mode – A simple software control signal from

the building automation system or a wall-mounted unit puts the unit into occupied mode. The unit controls compressor and fan operation to maintain occupied setpoints. High and low limits for occupied setpoints are software configurable.

● Unoccupied Mode – A simple software control signal

from the building automation system or a wall-mounted unit puts the unit into unoccupied mode for night setback operation. The unit controls compressor and fan operation to maintain unoccupied heating and cooling setpoints, which are also software configurable.

● After-hours Override Mode – Asimple software control

signal from the building automation system or a wallmounted unit can initiate after-hours heating or cooling in half-hour increments. Maximum override time is software configurable up to 9.5 hours. This feature can also be disabled in software.

● Reversing valve delay – When the compressor turns

off after heating mode, the reversing valve remains energized for 60 seconds before it returns to the normal cooling position to eliminate swishing. The reversing valve energizes 10 seconds before the compressor.

● Load Shed – Load shedding can be orchestrated by the

building automation system using the occupied/unoccupied command in software.

● Brownout Protection – An onboard sensor measures

input voltage and suspends compressor and fan operation if the supply voltage drops below 82% of the normal line voltage for a minimum of 10 seconds, creating an alarm available in software. The alarm automatically resets when the supply voltage returns to above 90% of normal.

BACnet®WSHP Unit Controller

IM 778 / Page 15

● Condensate Overflow Protection – A liquid sensor at

the top of the drain pan senses a high water level. Upon sensing water, cooling operation is suspended, while heating operation is allowed. The controller creates an alarm available in software. The alarm automatically resets when the water level returns to normal.

● Safety Control – The unit monitors refrigerant pressure

and generates separate high-pressure and low-pressure alarms available in software. While either alarm is active, compressor operation is suspended. In a refrigerant lowtemperature condition, an alarm occurs and the unit operates in cooling mode for 60 seconds to defrost the heat exchanger, after which compressor operation is suspended. These alarms can be reset in software or by cycling power to the controller.

● Attained Temperature and Water Temperature

Alarms – Attained temperature, water temperature alarms with software-adjustable setpoints are available in software. The controller samples supply air and records attained temperatures for heating and cooling. If after two hours of operation, the attained temperature does not meet the software-configurable setpoint for heating or cooling as appropriate, a software alarm occurs. The alarm automatically resets when the attained

temperature is within setpoints. The controller also monitors leaving water temperature. If the leaving water temperature is outside software-configurable setpoints, compressor operation is suspended and high or low water temperature alarms occur. The alarm automatically resets when the water temperature returns to within 6 deg. F of the setpoint.

● Unit Self-test Mode – While the unit is in occupied

mode, a self-test can be initiated via software. Upon initiation of the test, compressor operation is suspended for a minimum of five minutes, cooling attained temperatures are cleared, and attained temperature alarms are cleared. The unit then switches to full heat for four minutes and then records the attained supply air temperature. Compressor operation is then suspended for five minutes. The unit then switches to full cooling for four minutes and the attained supply air temperature is recorded. Attained temperature alarms are set if the attained temperatures failed to reach alarm setpoints during heating or cooling.

BACnet®WSHP Unit Controller

Page 16 / IM 778

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

GWYR

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GW1Y1A 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

IM 778 / Page 17

Programmable Electronic Thermostat (P/N 105570901)

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

Thermostat Connection Diagrams

Mark IV/AC Units – Unit Sizes 007-060

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)

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.

7-Day Programmable Electronic Thermostat w/Sensor (P/N 106710801)

P/N 106710801 Includes Thermostat, Wall Plate, and Wall Sensor

WSHP Mark IV/AC Board Low Voltage Terminal

OW2GW1Y1 F E L U A P V R C

GW1Y1 RRc C

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal

OW2GW1Y1 F E L U A P V R C

Sensor

GW1Y1 RRc C

Thermostat Terminals

S1 S2

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

2 3

Auxiliary Relay

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

2 3

Auxiliary Relay

Orange

Yellow

White

Orange

Yellow

White

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

2 3

Auxiliary Relay

Orange

Yellow

White

Page 18 / IM 778

Options on Mark IV/AC Units

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.

Motorized Valve & Relay for Unit Sizes 007 thru 060

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

⁄2"

while unit sizes 024 to 060 are

⁄4". Other thermostat combinations may be used. 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.

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 859004354 - Valve Relay Kit

R Y

TB3

TB2

TB1

R Y G W

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

GW1Y1R Rc C

Thermostat Terminals

Multiple Unit

Control

Panel

GWY C L

R Y G W

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

GW1Y1RRc C

Thermostat Terminals

Orange

Yellow

White

Auxiliary Relay

631

1 2 3

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

OW2GW1Y1 A R

Thermostat Terminals

Connector

Valv e

36" (915 mm)

Anti-Short Bushing

Lead Length

Conduit

Time Clock (by others)

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

Pins,

Female

Black to 6

White to 1

3 1

Plug

IM 778 / Page 19

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

7 6 5 4 3 2 1

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

64 58

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

Pump

Restart

Relay

7 6 5 4 3 2 1

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

64 58

Wiring Pump Restart Relay when Installed within the LWC Panel

Wiring Pump Restart Relay when Installed within a WSHP Control Box

Page 20 / IM 778

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)

4 321

(by others)

24VAC

4 321

24VAC

(by others)

24VAC

IM 778 / Page 21

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 Fan

Flash Green LED

Stop Comp.

Htg Mode?

Stop Comp.

Flash Yellow L ED

Stop Comp.

Turn On Red LED

R - W 2 ?

Start Comp.

Cooling Mode

Turn On Yellow LED

Stop Comp.

Reversing Valve On

Time Delay

Start Comp.

Yes

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

Page 22 / IM 778

Troubleshooting Water Source Heat Pump

Field wiring must comply with local and national fire, safety, and electrical codes, and voltage to the system must be within the limits shown in the job-specific drawings and unit electrical data plate(s). All power supply to unit must be disconnected when making field connections. Rigorously adhere to lockout and tagout procedures. Improper wiring or procedure can cause electric, personal injury or death.

DANGER

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

IM 778 / Page 23

Troubleshooting

The in and outs of R410A

Refrigerant 410A is a non-ozone depleting blend of two refrigerants HFC-125 and HFC-32 in a fifty percent mixture. Refrigerant 410A exhibits higher operating pressure and refrigeration capacity than R-22. R-410A refrigerant is intended for use in new air conditioning application that has traditionally been serviced by HCFC-22 or R-22. Due to higher capacity and pressure of R-410A, it is not recommended as a retrofit to existing R-22 systems.

Although R-410A is non-flammable at ambient temperature and atmosphere pressure, it can become combustible under pressure when mixed with air. (NOTE: R410A should not be mixed with air under pressure for leak testing. Pressure mixtures of dry nitrogen and R-410A

can be used for leak testing.)

Lubrication

R410A should be used only with polyolester (POE) oil. The HFC refrigerant components in R-410A will not be compatible with mineral oil or alkylbenzene lubricants. R-410A systems will be charged with the OEM recommended lubricant, ready for use with R-410A.

Charging

Due to the zeotropic nature of R-410A, it should be charged as a liquid. In situations where vapor is normally charged into a system, a valve should be installed in the charging line to flash the liquid to vapor while charging.

General 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.

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. Check filters 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. Record performance measurements of volts, amps, and water temperature differences (both heating and cooling). 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.

Make certain that the recycle or recovery equipment used is designed for R-410A. The pressure of R-410A refrigerant

is approximately 60 percent greater than that of R-22. Pressure gauges require a range up to 800 PSIG high side and 250 PSIG low side. Recovery cylinders require a 400 PSIG rating – do not put R-410A in a 300 PSIG rated cylinder.

(NOTE: because a water source heat pump operates under a wide range of water and air temperatures, the values printed below are to be taken as suggested pressure and temperatures.) All McQuay water source heat pumps are designed for commercial use. The units are designed for the cooling mode of operation and fail safe to cooling. The revising valve is energized for the heating mode of operation.

Superheat Head Pressure Water Delta T

8 to 14 degrees 335-355 PSIG 10° to 12°

All information above is based on ISO standard 13256-1 and are tested at these condition.

Recycle/recovery equipment must be designated for R-410A. R-410A pressure is greater than R-22. Improper equipment can cause severe injury or death.

WARNING

Page 24 / IM 778

High

Normal

Low

Normal

Low

Normal

Charge

Undercharge System Low Low Low High Low Low Low Low Pressure (Possible Leak)

Overcharge System High High High Normal High Normal High Pressure

Low Air Flow Heating High High High Low High Low High Pressure

Low Air Flow Cooling Low Low Low High High Low Low Temp

Low Water Flow Heating Low Low High Low High Low Temp Low Water Flow Cooling High High High High Low Low High High Pressure High Air Flow Heating Low Low Low Low High Low Low Low Temp

High Air Flow Cooling Low High Normal High Low Low Normal High Pressure High Water Flow Heating Normal Low Normal High Normal Normal Low High Pressure

High Water Flow Cooling Low Low Low Low High Normal Low Low Temp

TXV Restricted High Low High High Low Low

Normal

Low

Normal

Cooling Mode

Return Air

Reversing Valve

Conditioned Air

(Cooling)

Thermal

Expansion Valve

Co-Axial Heat

Exchanger

Blower

Coil –

Air to

Refrigerant

Heat

Exchanger

Water In Water Out

Sensing Bulb and Capillary Tube

Compressor

Air Water Safety

Head Suction Compressor Super Temp (loops) Temp Lock

Symptom Pressure Pressure Amp Draw Heat Subcooling Differential Differential Out

Heating Mode

Return Air

Thermal

Expansion Valve

Co-Axial Heat

Exchanger

Reversing Valve

Conditioned Air

(Heating)

Blower

Water In Water Out

Sensing Bulb and Capillary Tube

Compressor

Coil –

Air to

Refrigerant

Heat

Exchanger

Normal

Low

Troubleshooting Refrigeration Circuit

Cooling Refrigeration Cycle

When the wall thermostat is calling for COOLING, the reversing valve directs the flow of the refrigerant, a hot gas, leaving the compressor to the water-to-refrigerant heat exchanger. Here the heat is removed by the water and the hot gas condenses to become a liquid. The liquid then flows through a thermal expansion metering system to the air-to-refrigerant heat exchanger coil. The liquid then evaporates becoming a gas, at the same time absorbing heat and cooling the air passing over the surfaces of the coil. The refrigerant then flows as a low pressure gas through the reversing valve and back to the suction side of the compressor to complete the cycle.

Heating Refrigeration Cycle

When the wall thermostat is calling for HEATING, the reversing valve directs the flow of the refrigerant, a hot gas, leaving the compressor to the air-to-refrigerant heat exchanger coil. Here the heat is removed by the air passing over the surfaces of the coil and the hot gas condenses to become a liquid. The liquid then flows through a capillary thermal expansion metering system to the water-to-refrigerant heat exchanger. The liquid then evaporates becoming a gas, at the same time absorbing heat and cooling the water. The refrigerant then flows as a low pressure gas through the reversing valve and back to the suction side of the compressor to complete the cycle.

IM 778 / Page 25

NOTES

Page 26 / IM 778

NOTES

IM 778 / Page 27

NOTES

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 FCV007 Installation Manual

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