McQuay MPS003AYCK Installation Manual
Installat
ion and Ma
intenance Manual
IM 864
Group: Applied Systems
Part Number: 92-102421-01-00
Date: March 2007
Maverick I™
Commercial Packaged Rooftop System
Cooling Only or Heating & Cooling
Electric/Electric
Models MPS003AY – 005AY
3 to 5 Tons
™
ARI Standard
210/240 UAC
© 2007 McQuay International
2 IM 864
Table of Contents
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Checking Product Received . . . . . . . . . . . . . . . . . . . . 3
Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pre-Installation Check Points . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Outside Slab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rooftop Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conversion Procedure . . . . . . . . . . . . . . . . . . . . . . . . 8
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
208 Volt Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Indoor Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankcase Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pre-Start Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auxiliary Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Charge Information . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Heater Kit Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
Charge Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
IM 864
3
Introduction
This manual contains the installation and operating instructions for your packaged rooftop unit. There are a few precautions that should be taken to derive maximum satisfaction
from it. Improper installation can result in unsatisfactory operation or dangerous conditions.
Read this manual and any instructions packaged with separate
equipment required to make up the system prior to installation.
Give this manual to the owner and explain its provisions. The
owner should retain this manual for future reference.
Checking Product Received
Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should
be filed immediately with the shipping company. Check the
unit model number, electrical characteristics, and accessories
to determine if they are correct.
Equipment Protection From The
Environment
The metal parts of this unit may be subject to rust or deterioration in adverse environmental conditions. This oxidation could
shorten the equipment’s useful life. Salt spray, fog or mist in
seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such
as paper mills and petroleum refineries are especially corrosive.
If the unit is to be installed in an area where contaminants
are likely to be a problem, special attention should be
given to the equipment location and exposure.
1 Avoid having lawn sprinkler heads spray directly on the
unit cabinet.
2 In coastal areas, locate the unit on the side of the building
away from the waterfront.
3 Shielding provided by a fence or shrubs may give some
protection.
Regular maintenance will reduce the buildup of contaminents and help to protect the unit’s finish.
1 Frequent washing of the cabinet, fan blade and coil with
fresh water will remove most of the salt or other contaminants that build up on the unit.
2 Regular cleaning and waxing of the cabinet with a good
automobile polish will provide some protection.
3 A good liquid cleaner may be used several times a year to
remove matter that will not wash off with water.
Several different types of protective coatings are offered in
some areas. These coatings may provide some benefit, but the
effectiveness of such coating materials cannot be verified by
the equipment manufacturer.
The best protection is frequent cleaning, maintenance and
minimal exposure to contaminants.
The manufacturer’s warranty does not cover any damage or
defect to the air conditioner caused by the attachment or
use of any components, accessories or devices (other than
those authorized by the manufacturer) into, onto or in conjunction with the air conditioner. You should be aware that
the use of unauthorized components, accessories or
devices may adversely affect the operation of the air conditioner and may also endanger life and property. The manufacturer disclaims any responsibility for such loss or injury
resulting from the use of such unauthorized components,
accessories or devices.
▲▲
DANGER
!
Recognize this symbol as an indication of
Important Safety Information!
!
Proposition 65: This unit contains fiberglass insulation.
Respirable particles of fiberglass are known to the state of
California to cause cancer.
▲▲
WARNING
!
Disconnect all power to the unit before starting maintenance. Failure to do so can result in severe electrical shock
or death.
▲▲
DANGER
!
4 IM 864
Figure 1: Unit Dimensions – Bottom View
Figure 2 : Unit Dimensions
ILL 1316
ILL1305
2
2
2
2
9.56
44.13
4.5
4.5
2.25
72.25
14.44
3.25
RETURN
AIR
SUPPLY
AIR
20
20
13.13
13.13
4.63
ELECTRIC HEAT ACCESS
COMPRESSOR/
CONTROL BOX
ACCESS
24.25
18.19
11.13
7.22
46.5
75.5
35
CONTROL ENTRY
5IM 864
Figure 3: Unit Dimensions
Figure 4: Unit Dimensions – Back View
ILL 1304
ILL 1288
SUPPLY COVER
31.22
3.81
76.31
47.09
5.34
24
RETURN COVER/
OPTIONAL OUTDOOR
AIR HOOD LOCATION
CONDENSATE DRAIN
3/4” NPT FEMALE
BLOWER
ACCESS
COIL/FILTER
ACCESS
76.25
12.25
5.5
19.13
6.84
13.72
12.25
35
4.94
19.13
6 IM 864
Installation
General
1 PRE-INSTALLATION CHECK-POINTS
Before attempting any installation, the following points
should be carefully considered:
a Structural strength of supporting members.
(rooftop installation)
b Clearances and provision for servicing.
c Power supply and wiring.
d Air duct connections.
e Drain facilities and connections.
f Location for minimum noise.
2 LOCATION
These units are designed for outdoor installations. They
can be mounted on a slab or rooftop. They are not to be
installed within any part of a structure such as an attic,
crawl space, closet, or any other place where condenser
air flow is restricted or other than outdoor ambient conditions prevail. Since the application of the units is of the
outdoor type, it is important to consult your local code
authorities at the time the first installation is made.
Outside Slab Installation
(Typical outdoor slab installations are shown in Figures 5 and
6.)
1 Select a location where external water drainage cannot
collect around the unit.
2 Provide a level concrete slab extending 3" beyond all four
sides of the unit. The slab should be sufficient above
grade to prevent ground water from entering the unit.
IMPORTANT: To prevent transmission of noise or vibration,
slab should not be connected to building structure.
3 The location of the unit should be such as to provide
proper access for inspection and servicing.
4 Locate unit where operating sounds will not distrub
owner or neighbors.
5 Locate unit so roof runoff water does not pour directly on
the unit. Provide gutter or other shielding at roof level.
Do not locate unit in an area where excessive snow drifting may occur or accumulate.
6 Remove compressor shipping supports (if so equipped)
after installation.
Clearances
The following minimum clearances must be observed for
proper unit performance and serviceability.
1 Provide 48" minimum clearance at the front of the unit.
Provide 36" minimum clearance at the left and right side
of the unit for service access.
2 Provide 60" minimum clearance between top of unit and
maximum 3 foot overhang.
3 Unit is design certified for application on combustible
flooring with 0" minimum clearance.
4 See Figure 5 for illustration of minimum installation-ser-
vice clearances.
Rooftop Installation
1 Before locating the unit on the roof, make sure that the
strength of the roof and beams is adequate at that point to
ILL I308
Figure 5: Outside slab installation, basement or crawl
space distribution system
18”
12”
*
Allow 57" for
economizer on duct side.
*
Figure 6: Outside slab installation, closet distribution system. Slab floor construction.
ILL I309
IM 864
7
support the weight involved. (See specification sheet for
weight of unit.) This is very important and user’s respon-
sibility.
2 For rigging and roofcurb details, see Figures 7 and 8. Use
field-furnished spreaders.
3 For roofcurb assembly, see Roofcurb Installation Instruc-
tions.
4 If the roofcurb is not used, provisions for disposing of
condensate water runoff must be provided.
5 The unit should be placed on a solid and level roofcurb or
platform of adequate strength. See Figure 9.
6 The location of the unit on the roof should be such as to
provide proper access for inspection and servicing.
7 Remove compressor shipping supports (if so equipped)
after installation.
IMPORTANT: If unit will not be put into service immediately,
cover supply and return openings to prevent excessive condensation.
ILL I296
A
B
D
C
38
.25
CENTER
OF
GRAVITY
25.75
Figure 7: Package air conditioner – rigging for lifting
CORNER WEIGHTS BY PERCENTAGE
ABCD
23% 27% 23% 27%
ILL I300
ILL I301
Figure 8: Package air conditioner – roofcurb installation
8 IM 864
Ductwork
Ductwork should be fabricated by the installing contractor in
accordance with local codes and NFPA90A. Industry manuals
may be used as a guide when sizing and designing the duct
system - contact Air Conditioning Contractors of America,
1513 16th St. N.W., Washington, D.C. 20036.
The unit should be placed as close to the space to be air conditioned as possible allowing clearance dimensions as indicated.
Ducts should be run as directly as possible to supply and
return outlets. Use of non-flammable waterproof flexible connectors on both supply and return connections at the unit to
reduce noise transmission is recommended.
It is preferable to install the unit on the roof of the structure if
the registers or diffusers are located on the wall or in the ceiling. A slab installation could be considered when the registers
are low on a wall or in the floor.
On ductwork exposed to outside air conditions of temperature
and humidity, use a minimum of 2" of insulation and a vapor
barrier. Distribution system in attic, furred space or crawl
space should be insulated with at least 2" of insulation with
vapor barrier. One-half to 1" thickness of insulation is usually
sufficient for ductwork inside the air conditioned space.
Balancing dampers should be provided for each branch duct in
the supply system. Ductwork should be properly supported
from the structure.
When installing ductwork, consider the following items:
1 Noncombustible flexible connectors should be used
between ductwork and unit to reduce noise and vibration
transmission into the ductwork.
2 When auxiliary heaters are installed, use noncombustible
flexible connectors and clearance to combustible material
of 0" for the first 3 feet of discharge duct. Clearance to
unit top and side is 0".
Filters
This unit is provided with 2 - 25" x 16" x 1" disposable filters. When replacing filters, ensure they are inserted fully to
the back to prevent bypass.
Conversion Procedure
Downflow To Horizontal
1 Remove the screws and covers from the outside of the
supply and return sections.
2 Install the covers in the bottom supply and return open-
ings with the painted side up. See Figure 10. Use the
existing gasket to seal the covers.
3 Secure the supply cover to the base of the unit with 1
screw, engaging prepunched tab in unit base.
4 Secure the return cover to the base of the unit with
screws, engaging prepunched holes in the unit base.
Condensate Drain
The condensate drain connection of the evaporator is 3/4"
nominal female pipe thread.
IMPORTANT: Install a condensate
trap to ensure proper condensate drainage. See Figure 11.
Figure 9: Flat rooftop installation, attic or drop ceiling distribution system. Mounted on roofcurb. Curb must be
level.
ILL I310
Figure 10: Cover gasket detail
ILL I631
Figure 11: Condensate Drain
Do not, under any circumstances, connect return ductwork
to any other heat producing device such as a fireplace
insert, stove, etc. Unauthorized use of such devices may
result in fire, carbon monoxide poisoning, explosion, property damage, severe personal injury or death.
▲▲
DANGER
!
IM 864
9
Electrical Wiring
Field wiring must comply with the National Electrical Code*
and local ordinances that may apply.
*C.E.C. in Canada
Power Wiring
1 It is important that proper electrical power is available at
the unit. Voltage should not vary more than 10% from
that stamped on the unit rating plate. On three phase
units, phases must be balanced within 3%.
2 Install a branch circuit disconnect within sight of the unit
and of adequate size to handle the starting current.
Reference Figure 12 for proper location.
3 For branch circuit wiring (main power supply to unit dis-
connect), the minimum wire size can be determined from
Table A using the circuit ampacity found on the unit
nameplate.
4 This unit incorporates single point electrical connection
for unit and electric heat accessory.
5 Power wiring must be run in grounded rain-tight conduit.
Connect the power field wiring as follows:
a NO ELECTRIC HEAT - Connect the field wires
directly to the contactor pigtail in the electric heat
access area. Connect ground wire to ground lug.
b WITH ELECTRIC HEAT - Connect the field wires to
the terminal block on the electric heater kit in the electric heat access area. Connect the ground wire to the
ground lug on the heater kit.
NOTE: For field installation of a heater kit, follow the instructions
provided with the heater kit.
6 The pigtail wires in the electric heat access area are facto-
ry wired to the contactor in the control box.
7 DO NOT connect aluminum field wires to electric heat
kit power input terminals.
WARRANTY WILL BE VOIDED IF CONNECTIONS ARE
NOT MADE PER INSTRUCTIONS
Control Wiring (Class II)
1 Low voltage wiring should not be run in conduit with
power wiring.
2 Control wiring is routed through the 7/8" hole adjacent to
the compressor access panel. See Figure 2. Use a minimum #18 AWG thermostat wire. For wire lengths
exceeding 50', use #16 AWG thermostat wire. The low
voltage wires are connected to the unit pigtails which are
supplied with the unit in the low voltage connection box
located below the unit control box.
3 Figure 14 shows representative low voltage connection
diagrams. Read your thermostat installation instructions
for any special requirements for your specific thermostat.
NOTE: Units installed in Canada require that an outdoor
thermostat (30,000 min. cycles of endurance) be installed
and be wired with C.E.C. Class I wiring.
COPPER WIRE SIZE — AWG (1% VOLTAGE DROP)
300
250
200
150
100
50
Supply
Wire
Length
Feet
Circuit Ampacity
NOTE:
1. Wire size based on 60ºC type copper conductors below 100 ampacity. 2. Wire size based on 75ºC type copper conductors for 100 ampacity and above.
4
4
6
8
10
14
15
3
4
4
6
8
12
20
2
3
4
6
8
10
25
2
3
4
4
6
10
30
1
2
3
4
6
8
35
1/0
1
2
4
6
8
40
1/0
1
2
3
4
6
45
2/0
1/0
1
3
4
6
50
2/0
1/0
1
2
4
6
55
3/0
2/0
1/0
2
3
4
60
3/0
2/0
1/0
1
3
4
65
3/0
2/0
1/0
1
2
4
70
4/0
3/0
2/0
1/0
2
3
75
4/0
3/0
2/0
1/0
2
3
80
4/0
3/0
2/0
1/0
1
3
85
4/0
4/0
3/0
1/0
1
2
90
250
4/0
3/0
2/0
1
2
95
250
4/0
3/0
2/0
1
2
100
250
4/0
3/0
2/0
1
2
105
250
4/0
3/0
2/0
1/0
2
110
300
250
4/0
2/0
1/0
1
115
300
250
4/0
3/0
1/0
1
120
300
250
4/0
3/0
1/0
1
125
300
250
4/0
3/0
1/0
1
130
300
250
4/0
3/0
1/0
1/0
135
350
350
300
4/0
1/0
1/0
140
350
350
300
4/0
2/0
1/0
145
350
350
300
4/0
2/0
1/0
150
350
350
300
4/0
2/0
2/0
155
Table A
Figure 12: Recommended location of branch circuit
disconnect
TO POWER
BRANCH CIRCUIT DISCONNECT
TO CONTROL
10 IM 864
Internal Wiring
IMPORTANT: Some single phase models are equipped with a
single pole contactor. Caution must be exercised when servicing
as only one leg of the power supply is broken with the contactor.
Some models are equipped with electronically commutated blower motors which are constantly energized unless the main unit
disconnect is in the off position.
1 A diagram of the internal wiring of this unit is located on
the inside of the compressor access panel. If any of the
original wire as supplied with the unit must be replaced,
the wire gauge and insulation must be the same as original wiring.
208 Volt Applications
Transformer is factory-wired for 220 volts on 200/220 volt
models and must be changed for 200-volt applications. See
unit wiring diagram for 200-volt wiring.
Grounding
Thermostat
The thermostat should be mounted on an inside wall about
five feet above the floor in a location where it will not be
affected by unconditioned air, sun, or drafts from open doors
or other sources. READ installation instructions in thermostat
package CAREFULLY because each has some different
wiring requirements. The low voltage wiring should be sized
as shown in Table B.
Install the room thermostat in accordance with the instruction
sheet packed in the box with the thermostat.
Indoor Air Flow Data
Direct-drive blower models are shipped factory wired for the
proper speed at a typical external static. See Blower
Performance Data. Belt-drive blower models have motor
sheaves set for proper CFM at a typical external static.
Crankcase Heat (Optional)
Crankcase heat is not required on scroll type compressors, but
may be necessary for difficult starting situations.
Pre-Start Check
1 Is unit properly located and slightly slanted toward
indoor condensate drain?
2 Is ductwork insulated, weatherproofed, with proper
spacing to combustible materials?
3 Is air free to travel to and from outdoor coil? (See Figure
5.)
4 Is the wiring correct, tight, and according to unit wiring
diagram?
5 Is unit grounded?
6 Are field supplied air filters in place and clean?
7 Do the outdoor fan and indoor blower turn freely with-
out rubbing, and are they tight on the motor shafts?
8 Are the compressor shipping supports removed (if so
equipped)?
Startup
1 Turn thermostat to “OFF,” turn “on” power supply at
disconnect switch.
2 Turn temperature setting as high as it will go.
3 Turn fan switch to “ON.”
4 Indoor blower should run. Be sure it is running in the
right direction.
5 Turn fan switch to “AUTO.” Turn system switch to
“COOL” and turn temperature setting below room temperature. Unit should run in cooling mode.
6 Is outdoor fan operating correctly in the right direction?
ILL I312
Figure 13: Heater Kit Installation
The unit must be permanently grounded. A grounding lug is
provided in the electric heat kit access area for a ground
wire. Failure to ground this unit can result in fire or electrical
shock causing property damage, severe personal injury or
death.
▲▲
DANGER
!
Table B
FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS
SOLID COPPER WIRE - AWG.
3.0 16 14 12 10 10 10
2.5 16 14 12 12 12 10
2.0 18 16 14 12 12 10
50 100 150 200 250 300
Length of Run – Feet (1)
Thermostat Load -
Amps
(1) The total wire length is the distance from the furnace to the thermostat and back to the furnace.
NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18
AWG.
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