McQuay FMS Installation Manual

Installation & Maintenance Data IM 407-14

Vertical Water Source Heat Pump & Cooling Only Units

Group: WSHP Part Number: 106581201

Date: March 2002

Model nomenclature ............................................................ 2

Transportation and shortage ................................................ 2

Installation ....................................................................... 2–4

Electrical data ...................................................................... 5

Piping ............................................................................... 5,6

Cleaning and flushing system .............................................. 6

Start-up ........................................................................... 6, 7

Contents

Operating limits ................................................................... 7

Wiring diagrams ............................................................. 8–13

Unit operation .................................................................... 14

Thermostat Connections, Mark IV/AC units ....................... 15

Options for Mark IV/AC units ....................................... 16–20

Troubleshooting ................................................................. 21

Maintenance ...................................................................... 22

Model Nomenclature

W FDD 1 009 E Z

Product Category

W = WSHP

Product Identifier

See box below

Design Series

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

Nominal Capacity

007 = 7,000 009 = 9,000 012 = 12,000 015 = 15,000 019 = 19,000 etc. . .

McQuay Product Identifiers

FDD = Floor Mtd/DDC Controls/Ext. Range/Less Board FDS = Floor Mtd/DDC Controls/Std. Range FDE = Floor Mtd/DDC Controls/Ext. Range FME = Floor Mtd/Mark IV/Ext. Range FDL = Floor Mtd/DDC Controls/Std. Range/Less Board FMS = Floor Mtd/Mark IV/Std. Range

Coil Options

(None)

Voltage

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

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.

Transportation and Storage

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, the cartons should be opened at once 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

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

In the event that elevator transfer makes upended posi-

tioning unavoidable, absolutely insure that the machine is in

the normal upright position for at least 24 hours before operating.

Temporary storage at the jobsite must be indoors, completely shielded from rain, snow, etc. High or low temperatures naturally associated with weather patterns will not harm the conditioners. Excessively high temperatures of

140

F (60oC) may deteriorate certain plastic materials and cause permanent damage. In addition, the solid-state circuit boards may experience operational problems.

Installation

General

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 as requested by 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 be sure that the unit will be installed in the correct location.

4. Before installation, check the available closet dimensions versus the dimensions of the unit.

5. Pay attention to the location and routing of water 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, ceiling and electrical foremen together before installing any conditioners.

7. Remove shipping block from under the fan wheel.

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

9. On extra-quiet construction units with spring mounted compressors, remove the shipping block under the compressor.

Page 2 / IM 407

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 nonducted return air facing 90o to the door and the major access panels facing the door as in Figure 1A. Alternatively, the unit can have a ducted return air with the opening facing the door and the major access panels facing 90

Figure 1A. Typical closet installation with louver door return

to the door as in Figure 1B.

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 5.

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 1A and 1B.

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

Model Distance

007 – 012 .......................... 4 inches

015 – 019 .......................... 5 inches

024 – 030 .......................... 6 inches

036 – 042 .......................... 7 inches

048 – 060 .......................... 8 inches

Filter access

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

Heat Pump

With Left-Hand

Return Air Arrangement

Return

Air

Opt. Controls

Elec. Entrance

Main Access Panel

Condensate

Water Supply

Water Return

Louvered Door

RisersReturn Air Thru

Figure 1B. Typical closet installation with ducted return

Heat Pump

Return

Duct &

Grille

With Left-Hand

Return Air Arrangement

Air

Opt. Controls

Elec. Entrance

Main Access Panel Main Access Panel

Heat Pump

With Right-Hand

Return Air Arrangement

Opt. Controls

Elec. Entrance

Main Access Panel

Condensate

Water Supply

Water Return

Return Air Thru Louvered Door

Heat Pump

With Right-Hand

Return Air Arrangement

Opt. Controls

Elec. Entrance

NOTE: Minimum distance

Return

requirement for non-ducted

Air

units. (see chart above)

Return

Air

Duct &

Grille

Condensate

Water Supply

Water Return

Condensate

Water Supply

Water Return

Risers

IM 407 / Page 3

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 noninsulated 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 2. The transition piece must not have an angle greater than 30 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 3. 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.

or severe loss of air

Figure 2.

Trunk Duct

Square Elbow (Both Sides Internally Lined With Acoustic Insulation)

Branch Duct (Internally Lined)

Duct Transition

Canvas Collar

Discharge Collar (on Heat Pump)

Heat Pump

2 ft. x 2 ft Diffuser

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. 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 7.

Figure 3.

Sizes 007 thru 042 Sizes 048 & 060

Page 4 / IM 407

Electrical Data

General

1. Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electrical Code, whichever is applicable.

2. Apply correct line voltage to the unit. A 7⁄8" (22mm) or 11⁄8" (29mm) hole 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 time delay (dual element) fuses or an HACR circuit breaker for branch circuit overcurrent protection. See the nameplate for correct ratings.

230 Volt operation and 50 cycle units

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

Figure 4A. Figure 4B.

Disconnect and cap the red lead wire and interchange it with the orange lead wire on the primary of the 24 volt transformer. Three-phase 50 cycle units require a neutral wire for 230/50/1 power.

Fan speed change

All units have two-speed fan motors and are shipped for high speed operation. On unit sizes 007, 009 and 012, the change from high speed to low speed is done by removing the black wire from the fan relay and connecting the red wire to the fan relay (Figure 4A). On units sizes 015 through 060, each fan motor is supplied with a 5-pin terminal block mounted on the fan motor. To change from high speed to low speed, move the wire from the black #3 location to the red #4 location on unit sizes 015 through 042 or to the red #5 location on units sizes 048 and 060. On 575 volt units, add a jumper between black #3 and blue #4 for low speed operation. See Figure 4B.

COMMON (WHITE)

FAN

MOTOR

BROWN (CAPACITOR) BLACK (HIGH SPEED)

RED (LOW SPEED)

Piping

1. All units are recommended to 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 are connected to the same loop. A simple way to check for proper water balance is to take a differential temperature reading across the water connections. To insure proper water flow, the differential should be 10

A direct return system may also be made to 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 are usually connected to the unit by 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 although it is not recommended since no vibration or noise attenuation can be accomplished. The hard piping must have unions to facilitate unit removal. See Figure 5 for typical piping setup.

4. 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

F (5oC) to 14oF (8oC).

COMMON CAPACITOR

HIGH SPEED LOW SPEED

LOW SPEED

FAN

MOTOR

YELLOW 1

BROWN 2

BLACK 3

*RED 4 *RED 5

*On unit sizes 048 and 060, terminal 4 is colorcoded blue and terminal 5 is color-coded red.

JUMPER

position for the flow required.

5. 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.

6. Condensate piping can be steel, copper or PVC. Each unit is supplied with a

⁄8" (22mm) ODM copper stub.

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

⁄4" inch per foot (21mm per meter). Generally, the

than condensate trap is made of copper and soldered on the unit. See Figure 6. 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 a

⁄8" (22mm) sweat to FPT fitting to facilitate connection of a flexible vinyl, rubber or steel braided hose.

8. No point in the drain system may be above the drain connection of any unit.

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

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

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

IM 407 / Page 5

Figure 5. Figure 6.

Balancing Blower Motor Access

Flexible Hose With Brass Pipe Fitting

Electrical & Compressor Access

Isolator Pad

Note: Condensate drain connection must be minimum of 1" (25mm) below connection to heat pump.

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.

Valve With

Close-off

Supply

Return

Condensate

(38mm)

⁄2"

Electrical Access Panel

⁄2"

(38mm)

Optional Cleanout

⁄4'' Per Foot

(21mm Per Meter)

Cleaning and 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. Additionally, pressure operated valves only open when the compressor is operating.

Figure 7.

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially Connected Together

2. The system should be filled at the city water makeup connection with all air vents open. After filling, vents should be closed.

The contractor should start main circulator with pressure reducing valve makeup open. Vents should be checked in sequence to bleed off any trapped air to assure 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 (27oC).

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. Supplemental heater and circulator pump should be shut off. All drains and vents should be opened to completely drain down the system. Short circuited supply and return runouts should now be connected to the conditioner supply and return connections. Teflon tape is recommended over pipe dope for pipe thread connections. Use no 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 (27oC) water.

5. Refill the system with clean water. Test the 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.

6. Set the system control and alarm panel heat add setpoint

to 70

F (21oC) and the heat rejection setpoint to 85oF

C). Supply power to all motors and start the circulating

(29 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 and for air and water balancing.

Start-up

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

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

Page 6 / IM 407

3. All units 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 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 temperature difference. For example, if the cooling temperature difference is 15 ture difference should have been 12

Without automatic flow control valves, a cooling temperature difference of 10

⁄2 times greater than the heating mode

F (8oC), the heating tempera-

F (5oC).

F to 14oF (5oC to 8oC) is about right. Adjust the combination shutoff/balancing valve in the return line to a water flow rate which will result in the 10

F to 14oF (5oC to 8oC) difference.

5. Set thermostat to “Heat.” If 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 (18oC).

Measure the temperature difference between entering and leaving air and entering and leaving water. With entering water of 60 water should be 6

F to 80oF (16oC to 27oC), leaving

F to 12oF (3.3oC to 6.7oC) cooler, and

the air temperature rise through the machine should not

exceed 35oF (19oC). If the air temperature exceeds 35oF

(19

C), the airflow rate is probably inadequate.

If the water temperature difference is less than 6

(3.3

C), the water flow rate is excessive. If the water

temperature difference exceeds 12

F (6.7oC), 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, the following points should be checked: a. Is proper voltage being supplied to the machine? b. Is the proper type of thermostat being used? c. Is the wiring to the thermostat correct?

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

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 dirt clogged.

9. Check the unit 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.

Operating Limits

Environment

This equipment is designed for indoor installation only. Sheltered locations such as attics, garages, etc., generally will not provide sufficient protection against extremes in temperature and/or humidity, and equipment performance, reliability, and service life may be adversely affected.

Power supply

A voltage variation of ±10% of nameplate utilization voltage is acceptable. Three-phase system unbalance shall not exceed 2%.

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.

Additional information

1. Standard units — Units are designed to start and operate

in an ambient of 40 with entering water at 70 at the 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.

F (5oC), with entering air at 40oF (5oC),

F (21oC), with both air and water

2. Extended range units — Extended range heat pump

conditioners are designed to start and operate in an ambient of 40 entering water at 40

F (5oC), with entering air at 40oF (5oC), with

F (5oC), with both air and water at the 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.

Air and water limits

STANDARD EXTENDED

UNITS RANGE UNITS

Cooling Heating Cooling Heating Min. Amb. Air 50oF/10oC50oF/10oC40oF/5oC40oF/5oC Normal Amb. Air 80oF/27oC70oF/21oC80oF/27oC70oF/21oC Max. Amb. Air 100oF/38oC85oF/29oC 100oF/38oC85oF/29oC Min. Ent. Air ➀ ➁ 50oF/10oC50oF/10oC50oF/10oC40oF/5oC Normal Ent. Air, 80/67 db/wb 27/19oC21oC 27/19oC21oC Max. Ent. Air, 100/83 db/wb ➀ ➁ 38/28oC27oC 38/28oC27oC

F70oF 80/67oF70oF

F80oF 100/83oF80oF

Water enthalpy

Min. Ent. Water

➀ ➁

Normal Ent. Water 85oF/29oC70oF/21oC85oF/29oC70oF/21oC Max. Ent. Air,

➀ ➁

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.

Cooling Heating Cooling Heating

F/13oC55oF/13oC40oF/5oC40oF/5oC

F/43oC90oF/32oC 110oF/43oC90oF/32oC

110

IM 407 / Page 7

60 Cycle Wiring Diagrams — Mark IV/AC Units

Figure 8. Unit sizes 007 through 012 (208-230, 265 volts, single-phase) 060686404 Rev. A

Notes:

1. Mark IV/AC controller board contains a static sensitive microprocessor. Proper grounding of field service personnel is required or damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is used, transformer must be rewired by disconnecting the power 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.

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

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or G may introduce electrical noise. Never install relays in series with the inputs.

Figure 9. Unit size 015 (208-230, 265 volts, single-phase) 060856804 Rev. A

Notes:

1. Mark IV/AC controller board contains a static sensitive microprocessor. Proper grounding of field service personnel is required or damage to controller may result.

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

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or G may introduce electrical noise. Never install relays in series with the inputs.

Page 8 / IM 407

+ 16 hidden pages