Vertical Water Source Heat Pump & Cooling Only Units

Transcription

1 Installation & Maintenance Data IM Group: WSHP Part Number: Date: June 2006 Vertical Water Source Heat Pump & Cooling Only Units Models FDD, FDE, FDL, FDS, FME, FMS Contents Model nomenclature... 2 Transportation and shortage... 2 Installation Electrical data... 5 Piping... 5,6 Cleaning and flushing system... 6 Start-up... 6, 7 Operating limits... 7 Wiring diagrams Unit operation LED Status and Fault Output Status Thermostat Connections, Mark IV/AC units Options for Mark IV/AC units Troubleshooting Maintenance McQuay International

2 Model Nomenclature W FDD 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, = 9, = 12, = 15, = 19,000 etc... Coil Options (None) Voltage E = 208/ F = 208/ J = K = L = M= N = 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 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. 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 positioning unavoidable, absolutely insure that the machine is in 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. Page 2 of 24 / IM 407 Transportation and Storage Installation 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 o F (60 o C) may deteriorate certain plastic materials and cause permanent damage. In addition, the solid-state circuit boards may experience operational problems. 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.

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 nonducted return air facing 90 o 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 o 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 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 inches inches inches inches inches Filter access Each unit is shipped with a filter bracket for side filter removal. Figure 1A. Typical closet installation with louver door return Heat Pump With Left-Hand Return Air Arrangement Heat Pump With Right-Hand Return Air Arrangement Return Air Opt. Controls Elec. Entrance Opt. Controls Elec. Entrance Return Air NOTE: Minimum distance requirement for non-ducted units. (see chart above) Main Access Panel Main Access Panel Condensate Water Supply Condensate Water Supply Water Return Water Return Return Air Thru Louvered Door Risers Return Air Thru Louvered Door Figure 1B. Typical closet installation with ducted return Return Air Duct & Grille Heat Pump With Left-Hand Return Air Arrangement Opt. Controls Elec. Entrance Main Access Panel Heat Pump With Right-Hand Return Air Arrangement Opt. Controls Elec. Entrance Main Access Panel Return Air Duct & Grille Water Supply Water Return Condensate Condensate Water Supply Water Return Risers IM 407 / Page 3 of 24

4 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 o 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 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. Figure 2. Square Elbow (Both Sides Internally Lined With Acoustic Insulation) Duct Transition Branch Duct (Internally Lined) Canvas Collar Discharge Collar (on Heat Pump) Heat Pump Trunk Duct 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 of 24 / IM 407

5 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 1 1 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 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. Electrical Data 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. YELLOW 1 BROWN 2 BLACK 3 *RED 4 *RED 5 COMMON CAPACITOR HIGH SPEED LOW SPEED LOW SPEED FAN MOTOR COMMON (WHITE) BROWN (CAPACITOR) BLACK (HIGH SPEED) RED (LOW SPEED) FAN MOTOR JUMPER *On unit sizes 048 and 060, terminal 4 is colorcoded blue and terminal 5 is color-coded red. 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 o F (5 o C) to 14 o F (8 o C). 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 Piping 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 7 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 than 1 4" inch per foot (21mm per meter). Generally, the 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 7 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 of 24

6 Figure 5. Figure 6. Blower Motor Access Balancing Valve With Close-off Electrical Access Panel Flexible Hose With Brass Pipe Fitting Supply Return 1 1 2" (38mm) Optional Cleanout Electrical & Compressor Access 1 1 2" (38mm) Condensate Isolator Pad 1 4'' Per Foot (21mm Per Meter) 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. 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 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 o F (27 o C). While circulating water, the contractor should check 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 of 24 / IM 407 Return Runout Supply Runout Rubber Hose Mains Runouts Initially Connected Together Cleaning and Flushing System Start-up 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 o F (27 o C) 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 o F (21 o C) and the heat rejection setpoint to 85 o F (29 o 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 and for air and water balancing. 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.

7 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 times greater than the heating mode temperature difference. For example, if the cooling temperature difference is 15 o F (8 o C), the heating temperature difference should have been 12 o F (5 o C). Without automatic flow control valves, a cooling temperature difference of 10 o F to 14 o F (5 o C to 8 o C) is about right. Adjust the combination shutoff/balancing valve in the return line to a water flow rate which will result in the 10 o F to 14 o F (5 o C to 8 o C) 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 o F (18 o C). Measure the temperature difference between entering and leaving air and entering and leaving water. With entering water of 60 o F to 80 o F (16 o C to 27 o C), leaving water should be 6 o F to 12 o F (3.3 o C to 6.7 o C) cooler, and the air temperature rise through the machine should not 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/ volts min.; 127 volts max /60/ volts min.; 253 volts max. 265/60/ volts min.; 292 volts max. 230/50/ volts min.; 253 volts max. 460/60/ volts min.; 506 volts max. 380/50/ volts min.; 418 volts max. 575/60/ 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-up in an ambient of 40 o F (5 o C), with entering air at 40 o F (5 o C), with entering water at 70 o F (21 o C), with both air and water at the flow rates used in the ARI Standard rating test, for initial start-up in winter. Note: This is not a normal or continuous operating condition. It is assumed that such a start-up is for the purpose of bringing the building space up to occupancy temperature. Operating Limits exceed 35 o F (19 o C). If the air temperature exceeds 35 o F (19 o C), the airflow rate is probably inadequate. If the water temperature difference is less than 6 o F (3.3 o C), the water flow rate is excessive. If the water temperature difference exceeds 12 o F (6.7 o 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, 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. 2. Extended range units Extended range heat pump conditioners are designed to start-up in an ambient of 40 o F (5 o C), with entering air at 40 o F (5 o C), with entering water at 40 o F (5 o C), with both air and water at the flow rates used in the ARI Standard rating test, for initial start-up in winter. Note: This is not a normal or continuous operating condition. 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 Water enthalpy STANDARD EXTENDED UNITS RANGE UNITS Cooling Heating Cooling Heating Min. Amb. Air 50 o F/10 o C 50 o F/10 o C 40 o F/5 o C 40 o F/5 o C Normal Amb. Air 80 o F/27 o C 70 o F/21 o C 80 o F/27 o C 70 o F/21 o C Max. Amb. Air 100 o F/38 o C 85 o F/29 o C 100 o F/38 o C 85 o F/29 o C Min. Ent. Air ➀ ➁ 50 o F/10 o C 50 o F/10 o C 50 o F/10 o C 40 o F/5 o C Normal Ent. Air, 80/67 o F 70 o F 80/67 o F 70 o F db/wb 27/19 o C 21 o C 27/19 o C 21 o C Max. Ent. Air, 100/83 o F 80 o F 100/83 o F 80 o F db/wb ➀ ➁ 38/28 o C 27 o C 38/28 o C 27 o C Cooling Heating Cooling Heating Min. Ent. Water ➀ ➁ 55 o F/13 o C 55 o F/13 o C 40 o F/5 o C 40 o F/5 o C Normal Ent. Water 85 o F/29 o C 70 o F/21 o C 85 o F/29 o C 70 o F/21 o C Max. Ent. Air, ➀ ➁ 110 o F/43 o C 90 o F/32 o C 110 o F/43 o C 90 o F/32 o 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. IM 407 / Page 7 of 24

8 60 Cycle Wiring Diagrams Mark IV/AC Units Figure 8. Unit sizes 007 through 012 ( , 265 volts, single-phase) Rev. A 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 ( , 265 volts, single-phase) Rev. A 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. Page 8 of 24 / IM 407

9 Figure 10. Unit sizes 019 through 048 ( , 265 volts, single-phase) Rev. C 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 11. Unit sizes 060 ( volts, single-phase) Rev. C 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. IM 407 / Page 9 of 24

10 Figure 12. Unit sizes 024 through 060 ( volts, three-phase) Rev. B 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 13. Unit sizes 024 through 060 (460 and 575 volts, three-phase) Rev. B 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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 10 of 24 / IM 407

11 50 Cycle Wiring Diagrams Mark IV/AC Units Figure 14. Unit sizes 007 through 012 (230 volts, single-phase) Rev. A 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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 15. Unit sizes 015 through 019 (230 volts, single-phase) Rev. A 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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. IM 407 / Page 11 of 24

12 Figure 16. Unit sizes 024 (230 volts, single-phase) Rev. A 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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 17. Unit sizes 048 and 060 (230 volts, single-phase) Rev. C 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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 12 of 24 / IM 407

13 Figure 18. Unit sizes 024 through 042 (380 volts, three-phase) Rev. A 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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 19. Unit sizes 048 and 060 (380 volts, three-phase) Rev. A 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. Terminal block on Mark IV/AC board provides 24 VAC at terminals R and C. All other terminals are 24 VDC output. 3. All temperature and pressure switches are normally closed. 4. 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. IM 407 / Page 13 of 24

14 Figure 20. Typical MicroTech 2000 WSHP unit controller single circuit wiring diagram 1. Unit is factory wired for 208V operation. If 230V power supply is used, transformer must be wired by disconnecting the power lead from the red transformer primary wire. Place an insulation cap on the red transformer primary wire. 2. All temperature and pressure switches are normally closed. 3. Wires 71 and 72 used only on units with no factory installed options. Page 14 of 24 / IM 407

15 General Each unit has a printed circuit board control system. The low voltage output from the low voltage terminal strip on the control board is always 24 volts DC (direct current). Terminals R and C on the low voltage terminal strip supply 24 volts AC power. 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. Two types of units are available: electromechanical control units or Mark IV/AC control units. Both have 24 volt DC circuits on the output of the low voltage terminal strip. Each requires its own unique automatic changeover thermostat. Unit Operation Figure 29. Unit #1 Unit #2 Unit #3 Ground To Additional Units Mark IV/AC control units 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 28 shows the LED and fault output sequences. The 24 volt low voltage terminal strip is set up so R-G energizes the fan, R-Y1 energizes the compressor for cooling operation, R-W1 energizes the compressor and reversing valve for heating operation. The reversing valve is set up to be energized in the heating mode. The circuit board has a fan interlock circuit to energize the fan whenever the compressor is on if the thermostat logic fails to do so. The Mark IV/AC control board has a lockout circuit to stop compressor operation if any one of its safety switches opens (high pressure switch and low pressure switch on unit sizes 048 and 060). If the low temperature switch opens, the unit will go into the cooling mode for 60 seconds to defrost any slush in the water-to-refrigerant heat exchanger. After 60 seconds the compressor is locked out. If the condensate sensor detects a filled drain pan, the compressor operation will be suspended only in the cooling mode. The unit is reset by opening and closing the disconnect switch on the main power supply to the unit in the event the unit compressor operation has been suspended due to low temperature (freezestat) switch, high pressure switch, or low pressure switch on unit sizes 048 and 060. The unit does not have to be reset on a condensate overflow detection. The Mark IV/AC control board has a fault output signal to an LED on a wall thermostat. Figure 28 shows for which functions the fault output is on (sending a signal to the LED). The Mark IV/AC control board 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. The fan shuts off and the unit is put under control from 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 Figure 28. INDICATION LEDS FAULT 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. Time Clock 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 emergency shutdown modes by running additional wires between units to ground. 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 the control the heating and cooling operation. The Mark IV/AC control system is also set up for 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 29. 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 an 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 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 on, at minimum, one WSHP's need. The P and C terminals may be daisy-chained between 200 units. See page 19. Mark IV/AC Sequence of Operation 14-Position Terminal Strip Pin Designation Description 1 C Transformer ground (Ovac) 2 R Transformer supply (24vac) 3 V -DC power connection 4 P Pump request output 5 A Alarm fault output 6 U Unoccupied input 7 L Load shed input 8 E Remote shutdown input 9 F +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 IM 407 / Page 15 of 24

16 LED Status and Fault Output Status Board Status LED s Fault Output Mode Yellow Green Red Terminal A Occupied Off On Off Energized Unoccupied On On Off 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 output is de-energized during faults and when unit power is off. Remote Reset of Manual Lockouts The Remote Reset feature provides the means to remotely reset automatic lockouts generated by high-pressure and/or low-temperature (in heating) faults. When the Mark IV board is in automatic lockout due to one of these faults, and the cause of the fault condition has been alleviated, energizing the O-terminal for 10 seconds or more will force the Mark IV board to clear the lockout. A unit power cycle can also be used to clear an automatic lockout if the conditions causing the fault have been alleviated. Fault Retry To Minimize Nuisance Trips The Fault Retry feature helps to minimize nuisance trips of automatic lockouts caused by high-pressure and/or low-temperature (in heating) faults. This feature clears faults the first two times they occur within a 24-hour period and triggers an automatic lockout on the 3rd fault. The retry count is reset to zero every 24 hours. Yes Yes Yes Yes Yes Yes Yes Yes Read Outputs Check Timers Hi Pres. Sw? No Brown Out? No Low Temp Sw? No Lo Shed? No N S B? No Cond. Overflow? No R - W 1? No R -Y 1? No Stop Comp. Flash Red LED Stop Comp. Stop Fan Flash Green LED General Use and Information 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 sources may be used to operate Mark IV/AC board inputs. Stop Comp. Htg Mode? Yes Flash Yellow LED Stop Comp. Turn On Red LED R - W 2? Yes Start Comp. Cooling Mode Turn On Yellow LED Stop Comp. No No No Using Drive Using Drive Using Drive Terminal R (24vac) Terminal F (vdc) Terminal C (ground) De-energized Energized De-energized Energized De-energized Energized Place the Meters Red (+) Lead on Place the Meters Place the Meters Place the Meters on Black (-) Lead Black (-) Lead Black (-) Lead Input to be on C on V on R checked U, L, E, Y1, W1, 10 to 22 to 30 to 10 to 22 to 0vdc G, W2, O 14vac 26vac 33vdc 14vac 26vac Reversing Valve On Time Delay Start Comp. Start Comp. Page 16 of 24 / IM 407

17 Thermostat Connection Diagrams Mark IV/AC Units Unit Sizes 007 to Day Programmable Electronic Thermostat (P/N ) WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit1) Thermostat Terminals R C W1 Y1 W2 Y2 G Includes Thermostat and Wall Plate. Refer to the installation, operation & application guide (LIA217) for thermostat installation details Non-Programmable Electronic Thermostat (P/N ) Override (Optional) WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit1) Thermostat Terminals R C W1 Y1 W2 Y2 G O Includes Thermostat and Wall Plate. Refer to the installation, operation & application guide (LIA204-4) for thermostat installation details Optional Remote Sensor (P/N ) 1. Remove cover from remote sensor housing. 2. Select an appropriate location for mounting the remote sensor. 3. Mount remote sensor unit using hardware provided. 4. Install two strand shielded wire between remote sensor and thermostat. Shielded wire must be used. Do not run remote sensor wire in conduit with other wires. Thermostat S1 S2 Remote Sensor Wire 1 should run between the S1 terminal on the thermostat and the S1 terminal on the remote sensor Wire 2 should run between the S2 terminal on the thermostat and the S2 terminal on the remote sensor Connect the shielding of the wire to the S2 terminal on the thermostat 5. Disable the main sensor (R12) on the thermostat by cutting it from the circuit board. Cut R12 from circuit board Wire 1 Wire 2 S1 S2 IM 407 / Page 17 of 24

18 Multiple Unit Control Panel for Mark IV Up to 3 Units (Part No ) The 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-shelf relays. Multiple Unit Control Panel TB3 TB2 TB4 TB1 G W Y R C R Y G W R Y G W R Y G W WSHP Mark IV/AC Board Low Voltage Terminal Strip WSHP Mark IV/AC Board Low Voltage Terminal Strip WSHP Mark IV/AC Board Low Voltage Terminal Strip Thermostat Terminals R C W1 Y1 W2 Y2 G Up to 2 Units (Part No ) The 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 (Uterminal) 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-shelf relays. WSHP Mark IV/AC Board Low Voltage Terminal Strip Multiple Unit Control Panel G W Y C L R Y G W L WSHP Mark IV/AC Board Low Voltage Terminal Strip Thermostat Terminals R C W1 Y1 W2 Y2 G Page 18 of 24 / IM 407

19 Motorized Valve & Relay for Unit Sizes 007 to 060 Wired as shown below the motorized valve will open on a call for compressor operation. Valves for unit sizes 007 to 019 are 1 2" power-open spring-return, while unit sizes 024 to 060 are 3 4" power-open spring-return. 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. Valve Connector Anti-Short Bushing P/N /2" Valve Kit P/N /4" Valve Kit P/N Valve Relay Kit 36" (915 mm) Lead Length Conduit Pins, Female Plug Black to 6 White to 1 WSHP Mark IV/AC Board Low Voltage Terminal Strip Time Clock (by others) Orange Yellow White Daisy-chain to additional Mark IV/AC board U terminals Auxiliary Relay BL GN Auxilliary Relay (P/N ) WSHP Mark IV/AC Board Low Voltage Terminal Strip 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 Options on Mark IV/AC Units Orange Yellow White Auxiliary Relay 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. WSHP Mark IV/AC Board Low Voltage Terminal Strip WSHP Mark IV/AC Board Low Voltage Terminal Strip 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 normally open contacts will close Orange Yellow White Auxiliary Relay Orange Yellow White Auxiliary Relay 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. IM 407 / Page 19 of 24

20 Boilerless System Kit (BSK) P/N for Sizes 007 to 042 & P/N for Sizes 048 to 060 The BSK option for use with the Mark IV/AC control board provides the capability to control a remote duct heater. The duct heater must be provided with a low voltage control circuit that only requires a set of dry contacts for operation. The contacts shown on the Boilerless System board (terminals 1, 2, and 3) are used to control the remote duct heater, the N.O. contacts will close on a call for duct heater heat. POT1 provides a means to manually adjust the water temperature setpoint (adjustment range is 43 o F to 60 o F). The Normal/Override switch provides a means to manually force electric heat to always be used in place of heat pump heat when in the override position (default position is normal - heat pump heat). When the water temperature drops below the value of POT1, then the duct heater will be used instead of heat pump heat on a call for heat from the low voltage thermostat (not included). Wire Ends to be Field Connected to the Mark IV/AC Board RD RD BR 43 Ohm WH WH OR WH OR Orange Yellow White Auxiliary Relay WSHP Mark IV/AC Board Low Voltage Terminal Strip GR 4-pin Plug OR RD WH BK GR Boilerless System Board Normal Override Pot 1 Water Temperature Sensor Signal to remote duct heater control circuit YE The BSK field installed kits include the sheet metal enclosure with cover, wire harness, boilerless system board, auxiliary relay, and water temperature sensor. When used, one BSK is required for each unit. To use the BSK kit you attach the sheet metal enclosure to the unit as shown, route the 4-wire harness through knockouts and connect to the Mark IV/AC board, mount and connect and insulate the water temperature sensor on the water supply line, and then connect the duct heater control contacts to the duct heater control circuit. If night setback (U-terminal) is used, the duct heater will respond to the occupied W1 thermostat signal. The load shed input (L-terminal) cannot be used for other control functions when being used with the BSK. The BSK is a DC voltage device, when the BSK is used the thermostat must be wired for VDC operation (245 mm) ( ) (368 mm) ( ) 6.5 (165 mm) ( ) 4.12 (105 mm) ( ) 1.75 (44.5 mm) Page 20 of 24 / IM 407