Vertical Stack Water Source Heat Pumps

Transcription

1 Installation & Maintenance Manual IM 986 Group: WSHP Part Number: Date: August 2009 Vertical Stack Water Source Heat Pumps Model VHC Vertical Stack Chassis Model VHF Vertical Stack Cabinet Unit Sizes / R-410A Refrigerant 2009 McQuay International

2 Page 2 of 48 / IM 986

3 Table of Contents Model Nomenclature Vertical Stack Model VHF (Cabinet) Vertical Stack Model VHC (Chassis) Receiving, Storage & Handling Disassembling Upper & Lower Cabinet Sections Dimensional Data Unit Size Unit Size Pre-Installation Considerations Cabinet Configurations Typical Framing & Discharge Arrangements Critical Dimensions Framing Locations to Unit Openings Vertical Riser Stub-Outs Locations to Unit Knockouts Installation Procedure Risers & Cabinet Cleaning & Flushing Water System Power Wiring From Building to Unit Connect Condensate Drain Hose to Drain Stubout Water Connections Installing Unit Chassis Making Cabinet to Chassis Wiring Connections Installing & Wiring the Remote Control Node Installing the Return Air Grille/Panel Installing the Discharge Air Diffuser Twin Units Installation Controls MicroTech III Unit Controller Remote Reset Feature MicroTech III Controller Terminal Locations & Descriptions I/O Expansion Module MicroTech III Controller with Lon Module MicroTech III Controller with BACnet Module MicroTech III Controller with Lon Module on Board Diagram Typical Wiring Diagrams MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), PSC Motor /60Hz/1-Phase, Unit Sizes MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), PSC Motor /60Hz/1-Phase, Unit Sizes MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), X13 Motor /60Hz/1-Phase, Unit Sizes MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), X13 Motor /60Hz/1-Phase, Unit Sizes Start-up Additional Accessories (General) Thermostats & Temperature Sensors Troubleshooting The in and outs of R-410A Refrigeration Circuit The Water Source Heat Pump Unit MicroTech III Unit Controller IM 986 / Page of 48

4 Model Nomenclature Vertical Stack Water Source Heat Pump Cabinet (VHF) W VHF B E DP LRY F 12 S 088 Product Category W - WSHP Product Code VHF - Cabinet Design Series 1 2 Unit Size - Tons 009-3/4 Ton Ton /4 Ton /2 Ton /4 Ton Ton /2 Ton Ton Controls B - MicroTech III C - MicroTech III With LonWorks D - MicroTech III With BACnet Voltage A - 115/60/1 ph E /60/1 ph J /60/1 ph Secondary Drain Pan DP - Standard Galvanized Steel ST - Stainless Steel Cabinet Type " Cabinet Height " Cabinet Height " Cabinet Height " Cabinet Height Filter Option S - Standard 1" Throwaway P - 2" Pleated (Merv 7) Y - None Blower Motor 12-2-Speed PSC Motor 22 - High Static PSC Motor 32 - ECM Motor 33 - ECM X Motor Power Connection F - Fused Disconnect N - Non-Fused Disconnect H - HACR Breaker Supply Air Configuration LYY - Single Supply Outlet, Left Side RYY - Single Supply Outlet, Right Side FYY - Single Supply Outlet, Front Side BYY - Single Back Side Supply Outlet TYY - Single Top Supply Outlet LFY - Double Supply, Left Side and Front Side LRY - Double Supply, Left Side and Right Side LBY - Double Supply, Left Side and Back Side RFY - Double Supply, Right Side and Front Side RBY - Double Supply, Right Side and Back Side BFY - Double Supply, Back Side and Front Side LTY - Double Supply, Left Side and Top RTY - Double Supply, Right Side and Top BTY - Double Supply, Back Side and Top FTY - Double Supply, Front Side and Top LFT - Triple Supply, Left Side, Front Side and Top LRT - Triple Supply, Left Side, Right Side and Top FRT - Triple Supply, Front Side, Right Side and Top FBT - Triple Supply, Front Side, Back Side and Top BRT - Triple Supply, Back Side, Right Side and Top BLT - Triple Supply, Back Side, Left Side and Top YYY - Closed Supply Plenum for field modification Note: For illustration purposes only. Not all options available with all models. Please consult McQuay Sales Representative for specific availability. Page 4 of 48 / IM 986

5 Model Nomenclature Vertical Stack Water Source Heat Pump Chassis (VHC) W VHC B E A C AMY C Product Category W - WSHP Product Code VHC - Chassis Design Series 1 2 Unit Size - Tons 009-3/4 Ton Ton / 4 Ton /2 Ton /4 Ton Ton /2 Ton Ton Controls B - MicroTech III C - MicroTech III With LonWorks D - MicroTech III With BACnet Voltage A - 115/60/1 ph E /60/1 ph J /60/1 ph Coax Coil Construction C - Copper Inner - Steel Outer S - CuproNickel Inner - Steel Outer X - Special Chassis Construction AYY - Standard Fiberglass Insulation EYY - IAQ - Cellular Insulation AMY - Standard w/compressor Blanket EMY - IAQ w/compressor Blanket AYC - Standard w/e-coated Air Coil EYC - IAQ - Cellular w/e-coated Air Coil AMC - Standard w/comp Blanket and Coated Air Coil EMC - IAQ w/comp Blanket and Coated Air Coil Motorized 2-Way Isolation Valve C - 2-Way Motorized 1/2" Iso-Valve, General Close-Off Pressure N.C. (Normally Closed) V - 2-Way Motorized 1/2" Iso-Valve, General Close-Off Pressure N.O. (Normally Open) H - 2-Way Motorized 1/2" Iso-Valve, High Close-Off Pressure N.C. (Normally Closed) D - 2-Way Motorized 3/4" Iso-Valve, General Close-Off Pressure N.C. (Normally Closed) K - 2-Way Motorized 3/4" Iso-Valve, General Close-Off Pressure N.O. (Normally Open) J - 2-Way Motorized 3/4" Iso-Valve, High Close-Off Pressure N.C. (Normally Closed) Y - None X - Special Refrigerant A - R-410A X - Special Note: For illustration purposes only. Not all options available with all models. Please consult McQuay Sales Representative for specific availability. IM 986 / Page 5 of 48

6 Receiving and Storage Upon receipt of the equipment, check the carton and pallets for visible damage. Make a notation on the shipper s delivery ticket before signing. If there is any evidence of rough handling, immediately open the cartons to check for concealed damage. If any damage is found, notify the carrier within 48 hours to establish your claim and request their inspection and a report. The Warranty Claims Department should then be contacted. IMPORTANT This product was carefully packed and thoroughly inspected before leaving the factory. Responsibility for its safe delivery was assumed by the carrier upon acceptance of the shipment. Claims for loss or damage sustained in transit must therefore be made upon the carrier as follows: VISIBLE LOSS OR DAMAGE Any external evidence of loss or damage must be noted on the freight bill or carrier s receipt, and signed by the carrier s agent. Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a damage claim. The form required to file such a claim will be supplied by the carrier. CONCEALED LOSS OR DAMAGE Concealed loss or damage means loss or damage which does not become apparent until the product has been unpacked. The contents may be damaged in transit due to rough handling even though the carton may not show external damages. When the damage is discovered upon unpacking, make a written request for inspection by the carrier s agent within fifteen (15) days of the delivery date and file a claim with the carrier. Cabinet Skid (4-units per skid) Never stack cabinets higher than as illustrated in Figure 1 at any time during transportation or storage or damage may occur. Figure 1. Unit Cabinet Skid as Shipped and Stored Chassis Skid (4 per skid - stored two skids high) Never stack chassis higher than as illustrated in Figure 2 at any time during transportation or storage or damage may occur. Figure 2. Chassis Skids Stacked 2 High Maximum For storing, each carton is marked with up arrows. 6' Page 6 of 48 / IM 986 4' Storage and Operating Environment Temporary storage at the job site must be indoor, completely sheltered from rain, snow, etc. High or low temperatures naturally associated with weather patterns will not harm the units. Excessively high temperatures, 140 F (60 C) and higher, may deteriorate certain plastic materials and cause permanent damage. Storage Temperature: -40ºF (-40ºC) to 140ºF (60ºC) Operating Temperature: 32ºF (0ºC) to 140ºF (60ºC) Humidity: 10%RH to 90%RH Non-condensing PCB Material and Flammability Rating: IPC/ANSI FR or CEM material as required to meet UL 94V-0 flammability rating.

7 Handling Carefully check items against the bills of lading to verify all crates and cartons have been received. Cabinets and Chassis normally ship four to a pallet. Carefully inspect all units for shipping damage. Report damage immediately to the carrier and file a claim. Check the unit data plate to be sure the unit electrical agrees with the power supply available (Figures 3). Figure 3. Unit Components & Descriptions - Received as Assembled Cabinet with Chassis Shipped Separate 3 4 1b 1b 1 2 1a Unit Data Plate Stub-out Seals DO NOT handle units by the riser piping. Riser clamps hold the riser in position; they are not designed to support the cabinet weight. The clamps are removed after the unit is installed. Unit cabinets are factory assembled and wired and have individual thermostat control capability. They are installed by stacking one unit on top of the other. While installing, prevent dirt and other foreign matter from entering the risers and plugging lines or valves. See "Cleaning & Flushing Water System" on page 16. General Information McQuay Vertical Stack units are designed for use in multiple floor apartments, office buildings, hotels, nursing homes and other similar applications. They require a minimum amount of floor space and are designed for multiple discharge arrangement. Installation and maintenance must follow accepted industry practices as described in the ASHRAE Handbook, the National Electric Code, and other applicable standards. Install this equipment in accordance with regulations of authorities having jurisdiction and with all applicable codes. WARNING Installation and maintenance are to be performed by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. WARNING The installer must determine and follow all applicable codes and regulations. This equipment presents hazards of electricity, rotating parts, sharp edges, heat and weight. Failure to read and follow these instructions can result in property damage, severe personal injury or death. This equipment must be installed by experienced, trained personnel only. Chassis Data Plate! CAUTION Component Descriptions (Assembled Cabinet) 1. Cabinet assembly complete (without chassis) 1a. Pipe riser sets (inlet, outlet and condensate) 1b. Inner front panel and filter bracket 2. Cooling and heating chassis (shipped separate) 3. Return air grille/panel (accessory) 4. Double-deflection diffuser (accessory) Sharp metal edges are a hazard, use care when servicing to avoid contact with them. IM 986 / Page 7 of 48

8 Disassembling Upper and Lower Cabinet Sections The Vertical Stack unit cabinet ships completely assembled. If required, it may be disassembled into two (2) sections (upper-fan/discharge cabinet) and (lower chassis/return air cabinet) to make it easier to handle. To disassemble, do the following. 1. Remove risers (if received attached). 2. Remove the three (bottom row) screws on the back of the unit as shown in Figure 4. Note: Retain all screws for later use to reassemble unit in reverse order as described in steps 1-7. Number of screws will vary depending on unit size. 3. Carefully lay the unit down on its back and remove the remaining eight (8) screws on the left and right side of the cabinet (Figure 5). 5. Remove the ten (10) screws and lift off the front panel/filter rack to gain access to the cabinet interior (Figure 6). 6. Locate and remove the six (6) screws located inside the cabinet joining the upper and lower cabinet sections (Figure 7). Note: Pull the insulaton away from the walls of the cabinet interior to get access to the screws. 7. Separate the lower return air cabinet section from the upper blower/discharge cabinet section (Figure 8). Figure 4. Remove three (3) screws (bottom row) on the back of the unit. Figure 5. Remove remaining eight (8) screws on the left and right sides of the cabinet Four (4) screws located on left side of cabinet Figure 6. Remove the ten (10) screws from the front panel/filter rack. Figure 7. Remove the six (6) screws located on the interior of the unit. Return air cabinet section interior Back of Unit Figure 8. Separate the lower cabinet section from the upper cabinet Three screws (bottom row) Page 8 of 48 / IM 986

9 Dimensional Data Model VHC/VHF 18" 18" Cabinet Size Left Side View Front View Dimensions Top View Unit Size A B C D E F G J K L M N P Q 80" 18.07" 18.11" 37.50".88" 58.09" 2.38" 3.125" 2" 2" 6.72" 12.4" 7.9" 3.3" " 18.07" 18.11" 37.50".88" 58.09" 2.38" 3.125" 2" 2" 6.72" 12.4" 7.9" 3.3" 18" 18" Cabinet 92" 18.07" 18.11" 37.50".88" 58.09" 2.38" 3.125" 2" 2" 6.72" 12.4" 7.9" 3.3" 96" 18.07" 18.11" 37.50".88" 58.09" 2.38" 3.125" 2" 2" 6.72" 12.4" 7.9" 3.3" A R S T U V 80" 3" 3" 3.3" 4.50" 4.50" 88" 3" 3" 3.3" 4.50" 4.50" 92" 3" 3" 3.3" 4.50" 4.50" 96" 3" 3" 3.3" 4.50" 4.50" Table 1. Unit Size Discharge Openings Single Double Triple Single-Top Opening W H W H W H W H " 16" 14" 8" NR NR 12" 12" " 16" 14" 8" 14" 18" 12" 12" NR = Not Recommended IM 986 / Page 9 of 48

10 Dimensional Data Model VHC/VHF 24" 24" Cabinet Size Front View Left Side View Dimensions Page 10 of 48 / IM 986 Top View Unit Size A B C D E F G J K L M N P Q 80" 24" 24.04" 37.50".88" 58.08" 2.38" 4.54" 2" 3" 6.72" 12.13" 7.63" 3.13" " 24" 24.04" 37.50".88" 58.08" 2.38" 4.54" 2" 3" 6.72" 12.13" 7.63" 3.13" 24" 24" 92" 24" 24.04" 37.50".88" 58.08" 2.38" 4.54" 2" 3" 6.72" " 3.13" Cabinet 96" 24" 24.04" 37.50".88" 58.08" 2.38" 4.54" 2" 3" 6.72" 12.13" " A R S T U V 80" 3.09" 3.10" 3.12" 4.50" 4.50" 88" 3.09" 3.10" 3.12" 4.50" 4.50" 92" 3.09" 3.10" 3.12" 4.50" 4.50" 96" 3.09" 3.10" 3.12" 4.50" 4.50" Table 1. Unit Size Discharge Openings Single Double Triple Single-Top Opening W H W H W H W H NR NR 18" 10" 18" 10" 18" 18" NR NR 18" 14" 18" 10" 18" 18" NR = Not Recommended

11 Pre-Installation Considerations 1. To prevent damage to equipment, do not operate supplementary heating and cooling during the construction period. 2. Inspect the carton for any specific tagging numbers indicated by the factory per a request from the installing contractor. At this time the voltage, phase and capacity should be checked against the plans. 3. Check the unit size against the plans to verify that the unit is being installed in the correct location. 4. Before installation, check the available dimensions of the area where the unit is to be installed versus the dimensions of the unit. 5. Note the location and routing of water piping, condensate drain piping, and electrical wiring. The locations of these items are clearly marked on submittal drawings. 6. The installing contractor will find it beneficial to confer with piping, sheet metal, and electrical foremen before installing any unit. Figure 9. Typical Side by Side Unit Installation Note: Check the unit data plate for correct voltage with the plans before installing the equipment. WARNING Make sure all electrical ground connections are made in accordance with local code. WARNING The contractor shall cover the units to protect the machines during finishing of the building. This is critical while spraying fireproofing material on bar joists, sandblasting, spray painting and plastering. For Optimum Unit Performance and to Help Minimize Noise and Vibration Adhere to the "Critical Dimensions" for locations of framing and distances to the cabinet. Install a 1/4" thick vibration isolation pad under the entire footprint of the unit cabinet base. Be sure there are no kinks and that the stainless steel braided hoses do not come in contact with and vibrate on chassis and cause noise. Ensure there is no metal-to-metal contact between return air grille and cabinet and the discharge diffuser and the cabinet, use provided gaskets. Air balancing in ducted applications is critical for proper airflow at each diffuser. IM 986 / Page 11 of 48

12 Cabinet Configurations Single Side Discharge Double Side Discharge Side & Top Discharge Double Side & Top Discharge Single Discharge Top Only Closed Plenum Field Modification Required = Return Riser = Supply Riser = Drain = Return Air = Discharge Air = Top Discharge Page 12 of 48 / IM 986

13 Typical Framing & Discharge Arrangements Typical Ducted Application = Return Air = Discharge Air Note: All ducted applications require a unit that utilizes an ECM-X13 or ECM 2.3 motor (sizes ). X13 motors are factory set for 2-speeds, 2 and 4 tap. For ducted unit applications only position 1 and 2-speed motor taps should be used. Additionally, static pressure must not exceed 0.40 inch static. See table below. ECM-X13 Motor CFM - Sizes External Static Pressure (Ducted Applications) Unit Size Speed Speed 1 Speed 2 Speed 1 Speed 2 Speed 1 Speed 2 Speed 1 Speed 2 External Static Pressure, WC" IM 986 / Page 13 of 48

14 Critical Dimensions Framing Locations to Unit Openings Location of studs is critical for proper installation and fit up and can help to reduce unit noise due to vibration when properly installed. Critical Dimensions Vertical Riser Stub-Outs Locations to Unit Knockouts Note: If the unit cabinet was shipped without risers attached it will be necessary to remove the appropriate riser knockouts prior to positioning the cabinet and connecting to the riser stub outs. Unit Size = 4.54" Unit Size = 3.125" 1/2" Conduit Fitting for Electrical Supply Unit Front Return Air 58.08" 37.50" 2.38" Dimensions do not include 1/4" vibration isolation pad Table 1. Reference Locations for Framing Framing Locations Unit A B C *D E *F *G *H J K L M N 80" 18" 2.07" 6" 22.25" 58.75" 61" 79" 3.125" 3.125" 18" 18" 88" 18" 2.07" 6" 22.25" 58.75" 69" 87" 3.125" 3.125" 92" 18" 2.07" 6" 22.25" 58.75" 73" 91" 3.125" 3.125" 3.3" 7.9" 12.4" 96" 18" 2.07" 6" 22.25" 58.75" 77" 95" 3.125" 3.125" 80" 24" 2.125" 6" 28.25" 59.5" 63" 79" 4.54" 3.125" 24" 24" 88" 24" 2.125" 6" 28.25" 59.5" 71" 87" 4.54" 3.125" 92" 24" 2.125" 6" 28.25" 59.5" 75" 91" 4.54" 3.125" 3.13" 7.63" 12.13" 96" 24" 2.125" 6" 28.25" 59.5" 79" 95" 4.54" 3.125" * Dimension includes approximately 1/4" for vibration isolation pad Page 14 of 48 / IM 986

15 Installation Procedure! CAUTION Installation and maintenance is to be performed only by qualified personnel who are familiar with, and in compliance with state, local and national codes and regulations, and experienced with this type of equipment. Sharp edges and coil surfaces are potential injury hazards. Avoid contact with them. Risers and Cabinet 1. Position the cabinet and risers within the building pipe chase and align with the unit on the floor above and/or below (Figure 10). Figure 10. Position the Cabinet and Risers Riser Couplings Connect to Risers on Unit Above Inlet, Outlet and Condensate Risers Note: Refer to "Critical Dimensions", page 14 to determine the correct recess depth from the front of the unit to the drywall face. When the installation is complete, the return air grille/panel frame must meet to seal with the cabinet discharge opening and the discharge air diffuser duct must meet and seal with the discharge opening. 2. Using the riser extensions, make preliminary riser connections between the units above and or below to assure proper riser alignment (supply, return and condensate). See "Critical Dimensions" on page After all components are aligned properly, anchor the unit cabinet to the floor using the McQuay provided mounting brackets (Figure 11). 4. Locate the two (2) mounting brackets in the parts bag and position them near the back corners of the unit, or one on a side and one on the back, whichever location or combination is most suitable, as illustrated in figure 11. Cut away an area of the 1/4" isolation pad at the mounting bracket locations. Contractor is responsible for the appropriate fasteners to secure the brackets to the floor, as local codes dictate. Figure 11. Position the Cabinet for Securing to the Floor with Mounting Brackets (2) Stud Wall Floor Plate and Finish Wall Location Back of Unit 1/4" Isolation Pad Risers Through Floor Opening 1/4" Vibration Isolation Pad Provided Mounting Brackets (2) Fasteners (by others) IMPORTANT Riser Extensions Align and Connect to Couplings and Unit Above A field-supplied ¼ thick isolation pad should be installed now (Figure 10). Unit Front Unit Cabinet 3 1 /8" from Finished Wall IMPORTANT The cabinet must be centered between the wall studs and plumb vertically for the grille/panel frame and diffuser to properly align and seal to the cabinet. Use of a 4' level is recommended. Finished Wall Stud Wall Floor Plate IM 986 / Page 15 of 48

16 Note: Be sure that each riser stub-out (supply & return) are centered within the riser knockout in the cabinet (Figure 12). If there is a void between the stub-out and the stub-out seal on the cabinet interior, this indicates that the stub-out is not properly centered within the knockout. Figure 12. Center the Riser Stub-Outs in the Knockouts and within Seals on the Cabinet Interior WARNING Before furring-in units, hydrostatically test the risers and unit connection joints in accordance with local building codes, to make sure they are leak-proof. Note: Perform "Cleaning and Flushing Water System" Procedure Below. CAUTION When furring-in units make sure that no screws or nails penetrate the unit cabinet. Riser Knockouts Knockouts on Cabinet Exterior Cabinet Interior 9. Layout the stud wall floor plates and frame-in unit referencing Typical Framing & Discharge Arrangements on page 13 and Critical Dimensions on page 14 and table 1. Note: Before cutting and hanging drywall, remove the appropriate discharge air opening knockout. See Table 2). Protect unit from construction debris with a protective cover. Table 2. Discharge Knockout Openings Unit Size Discharge Openings Single Double Triple Single-Top Opening W H W H W H W H 14" 16" 14" 8" NR NR 12" 12" " 16" 14" 8" 14" 18" 12" 12" NR NR 18" 14" 18" 10" 18" 18" NR NR 18" 14" 18" 10" 18" 18" NR = Not Recommended Cleaning and Flushing Water System Stub-Out Connections with Valves Centered within Knockouts and Seals CAUTION Stub-Outs Seals The unit is not designed to support the weight of the risers. Anchor them securely to the building structure. 5. Anchor risers to the building structure to prevent vertical riser movement greater than, plus or minus one inch to allow for riser expansion or contraction. 6. Solder all supply and return riser connections to units above and/or below. 7. Remove riser ties used to secure the risers to the cabinet during shipping. CAUTION Prior to first operation of any unit, the water circulating system must be cleaned and flushed of all construction dirt and debris or damage will occur. 1. Prior to first operation of any unit, the water circulating system must be cleaned and flushed of all construction dirt and debris. If the units are equipped with water shutoff valves, either electric or pressure operated, the supply and return runouts must be connected together at each unit location. This will prevent the introduction of dirt into the unit (Figure 13). Page 16 of 48 / IM 986

17 Figure 13. Connections for flushing system piping Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. NOTICE It is not McQuay International s policy to make recommendations on water treatment. However, the general contractor or owner should contact a local water treatment company regarding water treatment. A fouled closed loop water system will lead to premature component failure. Adapter, MPT x Straight Pipe Thread included with flexible hoses Note: Use for making connections to the supply & return valves for the "Cleaning and Flushing Water System" procedure. 2. Fill the system at the city water makeup connection with all air vents open. After filling, close all air vents. The contractor should start main circulator with the pressure reducing valve open. Check vents in sequence to bleed off any trapped air, ensuring circulation through all components of the system. Power to the heat rejector unit should be off, and the supplementary heat control set at 80 F (27 C). While circulating water, the contractor should check and repair any leaks in the unit and surrounding 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 until the drain water is clean and clear. 3. Shut off supplemental heater and circulator pump and open all drains and vents to completely drain down the system. Short circuited supply and return runouts should now be connected to the unit supply and return connections. Do not use sealers at the swivel flare connections of hoses. 4. Flush system with water for 2 hours or longer until water is clean. 5. Refill the system with clean water. Test the water using litmus paper for acidity, and treat as required to leave the water slightly alkaline (ph 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Do not use automotive grade antifreeze (See Table 5 on page 18 for Antifreeze Correction Factors). Note: Contact a local water treatment company to confirm water clarity prior to unit operation. Dirty water will result in system wide degradation of performance and solids may clog system-wide valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life or causes premature failure. 6. Set the loop water controller heat add setpoint to 70 F (21 C) and the heat rejection setpoint to 85 F (29 C). Supply power to all motors and start the circulating pumps. After full flow has been established through all components including the heat rejector (regardless of season) and the vented air and loop temperatures have been stabilized, each of the units will be ready for check, test and start-up, air balancing, and water balancing. Table 3. Air Limits Standard Range Geothermal Range Units Units Cooling Heating Cooling Heating Min. Ambient Air 50 F/10 C 50 F/10 C 40 F/5 C 40 F/5 C Normal Ambient Air 80 F/27 C 70 F/21 C 80 F/27 C 70 F/21 C Max. Ambient Air 100 F/38 C 85 F/29 C 100 F/38 C 85 F/29 C Min. Entering. Air 50 F/10 C 50 F/10 C 50 F/10 C 40 F/5 C Normal Entering Air, 80 F/67 F 70 F 80 F/67 F 70 F db/wb 27/19 C 21 C 27/19 C 21 C Max. Entering Air 100/83 F 80 F 100/83 F 80 C db/wb 38/28 C 27 C 38/28 C 27 C Table 4. Water Limits Standard Range Geothermal Range Units Units Cooling Heating Cooling Heating Min. Entering. Water 55 F/13 C 55 F/13 C 30 F/-1 C 20 F/-6 C Normal Entering. Water 85 F/29 C 70 F/21 C 77 F/25 C 40 F/5 C Max. Entering. Water 110 F/43 C 90 F/32 C 110 F/43 C 90 F/32 C At ARI flow rate. 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. CAUTION Units must be checked for water leaks upon initial water system start-up. Water leaks may be a result of mishandling or damage during shipping. Failure by the installing contractor to check for leaks upon start-up of the water system could result in property damage. IM 986 / Page 17 of 48

18 Table 5. Antifreeze Correction Factors Ethylene Glycol 10% 20% 30% 40% 50% Cooling Capacity Heating Capacity Pressure Drop Propylene Glycol 10% 20% 30% 40% 50% Cooling Capacity Heating Capacity Pressure Drop Methanol 10% 20% 30% 40% 50% Cooling Capacity Heating Capacity Pressure Drop Ethanol 10% 20% 30% 40% 50% Cooling Capacity Heating Capacity Pressure Drop Power Wiring From Building to Unit Figure 23. Wire to Unit Switch! DANGER To avoid electrical shock, personal injury or death: 1. Installer must be qualified, experienced technician. 2. Disconnect power supply before installation to prevent electrical shock and damage to equipment. 1. Locate the electrical power supply wiring from the building and feed wiring through the 1/2" conduit fitting (strain relief) on the unit as shown in Figure 22 & 23, following local electrical codes and regulations. Figure 22. Supply Electric Wiring from Building to Unit 1/2" Knockout for Supply Wiring 2. If a remote wall-mounted thermostat is being used, install a 24-volt thermostat wiring cable with at least 6 wires from the unit low voltage terminal strip (Figure 24) to the thermostat location. Flexible Metal Conduit & Strain Relief 3. If a wireless remote thermostat was ordered to control the unit, it is recommended that the Remote Control Node (RCN) be installed now. Page 18 of 48 / IM 986

19 Figure 24. Low Voltage Terminal Strip for Thermostat Wiring Water Connections All piping connections should be made using good plumbing practices and in accordance with any and all local codes that may apply. 2-Speed Fan Switch Thermostat Low Voltage Terminal Strip Note: See specific thermostat installation manual for wiring and operation of thermostat. Install wall mounted thermostat while completing dry wall installation. Connect Condensate Drain Hose to Drain Stub Out 1. Remove the two (2) screws located along the back edge of the drain pan, holding it in place (Figure 25). 2. Adjust the direction of the condensate drain hose and slip it over the drain stub out. Using the provided clamp, secure the hose by tightening the clamp. 3. Reinstall the secondary drain pan with the two (2) screws removed in step 1. Figure 25. Connect Drain Hose to Drain Stub Out Unit Piping Connection Unit sizes 009 through 018 coil connections are gooseneck style, made of copper tubing with 1/2" FPT. Unit sizes 021 through 036 have 3/4" FPT connections (Figure 26). Shutoff/Balancing Valve Each heat pump requires a shutoff valve on both the supply and return risers for easy serviceability and removal of the chassis when necessary. We suggest using a factory installed 2-way motorized isolation valve on the return line of the chassis and a Auto Flow Regulator (AFR) installed on the supply line which allows proper water flow in a given size unit. Each valve package has 1/2" FPT or 3/4" FPT threaded connections (Figure 26). Figure 26. Typical Motorized Valve Piping FPT Return Connection 2-Way Motorized Valve Two (2) Screws Holding Pan in Place Drain Stub Out Auto Flow Regulator FPT Supply Connection Hose Clamp Adding Motorized Valve & Auto Flow Regulator The Vertical stack water source heat pump chassis can be configured with a 2-way motorized valve. The 2-way motorized valve is mounted on the return line of each unit and the Auto Flow Regulator (AFR) is mounted to the supply line. Valve assemblies terminate with either a 1/2" (unit sizes ) or 3/4" (unit sizes ) NPT threaded connection and will accommodate factory supplied hoses. IM 986 / Page 19 of 48

20 Make Flexible Hose Connections to the Supply and Return Valves From Riser Stub Outs 1. Using the specified supply and return hoses make supply and return hose connections to the riser stubouts (Figure 27). Note: The MPT straight pipe adapters can be removed from the swivel end of the flexible hoses now and threaded onto the chassis FPT supply and return pipe connections (Figure 28). This will make hose connections to the chassis easier when the chassis is partially installed. 2. Attach the (MPT) fixed hose ends to the female connections on the valves. Using two crescent wrenches, one to hold the valve pipe connection and the second on the hose end, tighten the connections. Figure 27. Make supply and return hose connections to the valves from the riser stub-outs Note: To complete the flexible hose connections to the chassis, only partially install the chassis into the cabinet as shown on page 21, Installing Unit Chassis. Important When Handling Chassis Note: If using a hand truck to move chassis, tip the chassis forward or back only, pivoting on the ends of the chassis rails. Tipping and pivoting the chassis side to side on the long edge of the rails will damage the rails and the rubber vibration isolators.! CAUTION Slots in the chassis rails that may be used as hand holds have sharp metal edges. To avoid personal injury, heavy protective gloves should be used while moving and lifting the unit chassis. Figure 29. Tip Chassis Front to Back Only, Pivoting on the Ends of the Rails Flexible Hose 2-Position Hand Valve Do not tilt chassis side to side on long edge of rails or damage will occur Tilt chassis front to back on end of rails when handling and moving Figure 28. Flexible Return and Supply Hoses (Field-installed) Assembled Length Fixed End, MPT Female Swivel Adapter, MPT x Straight Pipe Thread Note: Connects to the chassis FPT supply & return connections. Page 20 of 48 / IM 986

21 Installing Unit Chassis 1. Thread the MPT adapters removed from the swivel ends of the flexible hoses onto the chassis FPT supply and return pipe connections. Using two crescent wrenches, one to hold the chassis pipe connection and the second on the adapter fitting, tighten the connections. 2. Install the chassis by sliding it into the cabinet opening until the chassis support rails sit on the cabinet rails. Slide the chassis into the cabinet until there is approximately a 10" space between the chassis coil and the cabinet. This will allow adequate clearance to connect the flexible hoses to the chassis coil. For safety, place a 6" high block under the chassis rails to support the chassis as shown in Figure 30. Figure 30. Slide chassis partially into the unit cabinet Approximately 10" gap to make hose connections Figure 31. Slide Chassis into Cabinet Leaving a 10" Gap for Clearance to Make Flexible Hose Connections Return Connection Supply Connection Making Cabinet to Chassis Wiring Connections 1. Locate the wires and plugs in the upper fan section of the unit that connect to the unit chassis. 2. Plug in the wires from the top cabinet section into the proper molex connectors on the chassis (Figure 32). Figure 32. Plug unit component wiring from the top cabinet section into the proper connectors on the chassis (Unit Size Chassis Shown) 6" high blocks to support chassis Main Power Connector Note: On unit sizes the Main Power Receptacle and Thermostat Connector locations are switched Fan Control Connector 2. Thread the female swivel ends of the hoses on to the water supply and return connections. Using two crescent wrenches, one to hold the straight MPT adapter and the second on the flexible hose swivel, tighten the connections. (Figure 31). Thermostat Wiring Connector 2. Push the chassis into the cabinet until it makes contact with the stops on the rails at the rear of the cabinet. Note: Be sure there are no kinks and that the stainless steel braided hoses do not come in contact with and vibrate on chassis and cause noise. Also be sure the wires do not hang up as the chassis is pushed into the cabinet. IM 986 / Page 21 of 48

22 Installing the (Optional) Remote Control Node (RCN) For Use With The Optional Wireless Thermostat Figure 34. Connect Wires to the RCN Terminals and snap the plastic standoffs onto Board! DANGER Plastic Standoffs (4) Disconnect all electrical power before servicing unit. Electrical shock will cause severe injury or death. 1. Remove the panel with the low voltage terminal strip by removing two (2) screws at the front of the cover and three (3) located on the underside. (Figure 33). The wires connected to the manual fan speed switch may be removed for easier access. Note: There are two methods for installing the RCN to the unit. The RCN mounts on the back of the bezel (blank control pad) and this assembly snaps into the knockout on the face of the unit. This method is not recommended since future replacement is more difficult. The preferred method for a new unit installation is illustrated below (Figures 33 24). Remote Control Node (RCN) Terminals on Back of Low Voltage Terminal Strip RCN Terminals Figure 33. Remove the Cover Plate with the Low Voltage Terminal Strip 3. Snap the plastic standoffs into the RCN as illustrated in Figure Reach inside the area behind the removed terminal strip cover and up behind the knockout. Align the standoffs on the board with the provided standoff holes on the knockout plate and snap the standoffs into the holes (Figure 35). Figure 35. Secure the RCN to the Unit with the Standoffs 2. Connect the provided wiring to the RCN terminals as shown in Figure 34. Plastic Standoffs (4) RCN RCN to Low Voltage Terminal Connectors 5. Connect the RCN wires with connectors to the low voltage terminals and reinstall the terminal strip cover. Page 22 of 48 / IM 986

23 Installing The Return Air Grille/Panel Figure 37. Install the Bottom Panel Door Seal to Cabinet 1. Apply the seal gaskets as illustrated in Figures 36 & 37. Apply the gasket to the back inside edge on the top and two sides of the door frame so that the door frame seals with the cabinet return air opening when installed (Figure 36). Apply the bottom panel door gasket to the underside of the flange on the cabinet return air opening as shown in Figure 37. Note: Shims should be used to make up the space between the studs and the panel frame at the locations of the fasteners on the panel frame (4). Adhere them to the panel frame to keep them in place (Figure 37). Seal Gasket Applied to the Underside of the Cabinet Bottom Flange Figure 36. Installing the Panel Door Frame Shims to Make Up Space Between Framed Opening and Panel Door Frame Seal Gasket Applied to the Inner Edge on the Back of the Panel Door Frame along top and two sides Door Panel Bottom Flange to Slide Beneath Cabinet Flange 2. Install the return air grille/panel assembly (Figure 36). Center, level and plumb the frame inside the framed opening. Push the assembly into the opening until the gaskets compress against the cabinet and the frame face is tight to the finished wall. Note: Be sure the bottom flange of the door frame slides beneath the cabinet flange, as shown in Figure 36. This seal must compress between the bottom panel flange and the bottom cabinet flange when the installation of the panel door frame is complete 3. Check that the panel door frame is centered within the opening and seals completely to the cabinet return air opening. Also confirm that the room side flange of the frame is level, plumb and firmly against the drywall. Secure the hinged panel door frame with the 4 screws provided. Seal Gasket on Underside of Cabinet Flange. Door Panel Flange Slides Underneath and Compresses to Cabinet IM 986 / Page 23 of 48

24 Installing The Discharge Air Diffuser 1. Adhere the provided 1/2" foam seal to the face of the cabinet around the perimeter of the discharge air opening (Figure 38). 2. Insert the diffuser into the wall opening and align the frame with the foam seal. Note: To avoid bending the adjustable discharge louvers do not press on them 3. Push the diffuser frame in until it compresses against the foam seal and the room side frame is flush against the drywall. Be sure the diffuser frame is level and plumb and secure it with the two (2) screws provided. Note: When installed correctly the diffuser frame should seal to the cabinet discharge air opening and no discharge air will be lost between the unit and the wall cavity. Figure 38. Installing the Discharge Air Diffuser Foam seal Foam seal applied to the cabinet face, around perimeter of discharge air opening Diffuser flange compresses into the foam seal Double-deflection Diffuser Page 24 of 48 / IM 986

25 Twin Units Installation Twin opposite hand units share a common riser system; i.e., supply, return, and drain riser. This is commonly called a master/secondary arrangement. The master unit is shipped with the risers attached. These special risers have stub-outs for both the master unit and the secondary unit which must be field connected and the following procedures must be followed for all twin unit installations. 1. Secondary units ship without risers and share common risers with the master unit. Knockout holes on the cabinet are provided for the 6" stub outs to make piping connections to the coil supply and return and the condensate drain. Figure 39. Twin Unit Arrangement (Side by Side) 2. Master units are offered in two-pipe systems with either right-hand or left-hand connections. Secondary units are offered to accommodate internal connections to any of these riser systems or locations. 3. The riser location (right or left) is determined by facing the return air grille panel. The risers are located on either the right or left of the unit. This defines the riser location. See Unit Configurations on page The riser block-off plates are located in the base of the secondary unit. Block-offs must be installed on the secondary unit before putting it into position. Master Unit Secondary Unit in Adjoining Room 6" Stubs on Master Unit Risers for Secondary Unit Stud Wall Separating Rooms Common Risers IM 986 / Page 25 of 48

26 MicroTech III Unit Controller The MicroTech III Unit Controller includes built-in features such as random start, compressor time delay, shutdown, condensate overflow protection, defrost cycle, brownout, and LED/fault outputs. Table 6 shows the LED and fault output sequences. The unit has been designed for operation with either a unit mounted thermostat or a microelectronic wall thermostat, selected by the manufacturer. Do not operate the unit with any other type of wall thermostat. Each unit has a printed circuit board control system. The low voltage output from the low voltage terminal strip is AC voltage to the wall thermostat. R is A/C voltage output to the wall stat. The 24 volt low voltage terminal strip is set up so R-G energizes the fan only. R-Y1 energizes the compressor for cooling operation, R-W1 energizes the compressor and reversing valve for heating operation. The reversing valve is energized in the heating mode. The circuit board has a fan interlock circuit to energize the fan whenever the compressor is on if the thermostat logic fails to do so. The output to the wall stat is AC current. Terminal (R) on the wall stat can be connected to terminal (R) on the PC board for AC voltage. R = AC current R to G = fan only R to Y1 = cooling R to W1 = heat The MicroTech III unit controller has a lockout circuit to stop compressor operation if any one of its safety devices is triggered (high pressure switch and low temperature sensor). If the low temperature sensor is triggered, 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 sensor or high pressure switch. The unit does not have to be reset on a condensate overflow detection. The MicroTech III unit controller fault output sends a signal to an LED on a wall thermostat. Table 6 shows for which functions the fault output is on (sending a signal to the LED). Page 26 of 48 / IM 986 Table 6. MicroTech III unit controller LED & fault outputs Mode / Fault Status LED s Thermostat Alarm Light Yellow Green Red Output-Terminal A Occupied, Bypass, Standby, or Tenant Off On Off Energized Override Unoccupied On On Off Energized Condensate Overflow On Off Off De-engergized High Pressure 1 Fault Off Off Flash De-energized Low Pressure 1 Fault Off Off On De-energized Low Temperature 1 Fault Flash Off Off De-energized Brownout Off Flash Off De-energized Emergency Shutdown Off Flash Off De-energized Room/Return Air or Low Temp Sensor 1 Failure Flash Flash On De-engergized Service Test Mode Enabled 1 On On Off De-energized Serial EEPROM Corrupted On On On De-energized Network Offline Received Off Off Off De-enegized 1 Compressor relay/compressor terminal is labeled COMP, switched line of the same electric input as any of the L1 terminals. Remote Reset Feature The Remote Reset feature provides the means to remotely reset automatic lockouts generated by highpressure and/or low-temperature (in heating) faults. When the MicroTech III unit controller 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 MicroTech III unit controller 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. The Intelligent reset feature helps to minimize nuisance trips of automatic reset lockouts caused by highpressure 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. The MicroTech III unit controller has built-in night setback operation. A grounded signal to the U terminal on TB3 of the unit control puts the unit into the unoccupied mode for night setback operation. Fan operation terminates and unit control will only respond to signal at the W2 terminal. Daytime heating and cooling operation is locked out. +24VAC to W2 energizes the compressor and reversing valve for heating operation. Night setback operation can be overridden for two hours by energizing the O on the TB2 terminal of the unit control for 3 seconds. Day thermostat setpoints then control the heating and cooling operation. The MicroTech III unit controller also accommodates shutdown operation on receipt of a grounded signal to the E input, respectively, on TB3 input terminal of the unit control.

27 MicroTech III Unit Controller Terminal Locations and Descriptions H VAC Power Input H1-2 C 24 VAC Common H2-1 SL1 Fan Output - Switched L1 H2-2 Blank Terminal H2-3 N Fan Neutral H3-1 HP1-1 High Pressure Switch 1 Input Terminal 1 H3-2 HP1-2 High Pressure Switch 1 Input Terminal 2 H4-1 Discharge Air Temp Common H4-2 Discharge Air Temp Signal H4 - Leaving Water Temp Common H4-4 Leaving Water Temp Signal H5-1 1 I/O Exp Module Common (Gnd) H5-2 I/O Exp Module Common (Gnd) H5 - I/O Exp Module +5 VDC H5-4 I/O Exp Module SPI CE1 H5-5 I/O Exp Module SPI CLK H5-6 I/O Exp Module SPI OUT H5-7 I/O Exp Module SPI IN H5-8 I/O Exp Module +12 VDC H5-9 I/O Exp Module 24 VAC H5-10 I/O Exp Module 24 VAC H5-11 Spare H5-12 Spare H6-1 1 Condensate Overflow Signal Input H6-2 Low Temp 1 Sensor Common H6 - Low Temp 1 Sensor Signal H6-4 Low Pressure Switch 1 Source Voltage H6-5 Low Pressure Switch 1 Signal H6-6 Reversing Valve 1 Common H6-7 Reversing Valve 1 Output H7-1 1 Dummy Terminal H7-2 Dummy Terminal H7 - Red LED Output H7-4 Green LED Output H7-5 Yellow LED Output H7-6 Red-Green-Yellow LED Common H8-1 1 Isolation Valve/Pump Request Relay N/O H8-2 Isolation Valve/Pump Request Relay N/C H8-24 VAC Common H9-1 1 Return Air Temperature Signal H9-2 Return Air Temperature Common TB1-1 1 Room Sensor LED Output TB1-2 2 Fan Mode / Heat-Cool-Auto Input TB1-3 3 Setpoint Adjust Input TB1-4 4 Room Temperature Sensor / Tenant Override TB1-5 5 DC Signal Common Test-1 R 24 VAC Test-2 W2 Heat Stage 2 Input Test-3 W1 Heat Stage 1 Input Test-4 Y2 Cool Stage 2 Input Test-5 Y1 Cool Stage 1 Input Test-6 G Fan TB2-1 R 24 VAC TB2-2 A Alarm Output TB2-3 W2 Heat Stage 2 Input TB2-4 W1 Heat Stage 1 Input TB2-5 Y2 Cool Stage 2 Input TB2-6 Y1 Cool Stage 1 Input TB2-7 G Fan Input TB2-8 O Tenant Override Input TB2-9 C 24 VAC Common TB3-1 E Mark IV Emergency Shutdown Input TB3-2 U Mark IV Unoccupied/Occupied Input L1-1 L1-1 Line Voltage Terminal 1 L1-2 L1-2 Line Voltage Terminal 2 L1-3 L1-3 Line Voltage Terminal 3 N1 N1 Neutral Terminal 1 N2 N2 Neutral Terminal 2 N3 N3 Neutral Terminal 3 Table 7. Configuration Jumper Settings Jumper Description Options JP1 Mode Open for normal operation mode Shorted for service/test operation mode JP2 Fan operation only applies to Open for continuous fan operation network controls Shorted for cycling fan operation JP3 Freeze protection Open for water freeze protection Shorted for antifreeze protection JP4 Future spare Future spare JP5 Set point adjustment range only Open for adjustment range of -3.0 to +3.0 F applies to network controls with a Shorted for 50 to 90 F adjustment range room temperature sensor JP6 Room control type Open for thermostatic room control Shorted for room temperature sensor control, MicroTech III only JP7 Future spare Future spare JP8 Future spare Future spare IM 986 / Page 27 of 48

28 Note: A random start delay time between 180 and 240 seconds is generated at power up. Location of Configuration Jumpers on the MicroTech III Unit Controller Figure 40. MicroTech III Unit Controller Terminal Locations Page 28 of 48 / IM 986

29 I/O Expansion Module For installation and operation information on MicroTech III unit controller and other ancillary components, see: IM MicroTech III Unit Controller for Water Source Heat Pumps (LonWorks). The I/O Expansion Module is a field-installed or factory installed option. It is an extension of the MicroTech III unit controller and provides extra functionality. The I/O Expansion Module has 2 main purposes: The I/O Expansion Module has outputs to control electric heat on a standard Water Source Heat Pump. The I/O Expansion Module has an independent LED annunciator to identify operational fault conditions on second stage equipment. Figure 41. I/O Expansion Module Configuration Jumper Terminals Features Jumper Terminals Second Circuit High pressure switch Low pressure switch Low suction line temperature sensor Compressor output Reversing valve Standard Heat Pumps / Single Circuit Units Monitors entering water temperature for boilerless electric heat control Outputs for medium and high speed fan controls. Table 8. I/O Expansion Module LED & Fault Outputs Note: Mode / Faults are listed in order of priority. 1 Boilerless electric heat only 2 Alarm/fault LED indications take precedence over service test mode LED indication. The controller shall use service test mode if the service test mode jumper is installed, even if the LED s indicate an alarm/fault. Table 9. I/O Expansion Module Jumper Designations Jumper Description Options JP1 Number of Open for single compressor Compressors Shorted for dual compressor JP2 Hot Gas/ Open to disable reheat Water Reheat Shorted to enable reheat JP3 and JP4 open for no supplemental heat JP3 Supplemental JP3 open, JP4 shorted for & JP4 Heat Type boilerless electric heat JP3 and JP4 shorted is an invalid setting JP5 and JP6 open for single-speed fan JP5 open, JP6 shorted for JP5 Fan Speed three-speed fan & JP6 Selection JP5 shorted and JP6 open for two-speed fan JP 5 and JP6 shorted is an invalid setting JP7 Compressor Open for single-speed compressor Speed Type Shorted for two-speed compressor JP8 Mode / Fault Future Spare Status LED's Yellow Green Red Thermostat Alarm Light Output Terminal A Invalid Configuration Jumper Setting Flash Flash Off De-energized Base Board Communication Fail Off Flash Flash N/A High Pressure #2 Fault Off Off Flash De-energized Low Pressure #2 Fault Off Off On De-energized Low Suction Temp #2 Fault Flash Off Off De-energized Sensor Failures Low Suction Low Suction Temp #2, Flash Flash On De-energized 1 EWT (w/ Boilerless EH only) 2 Service Test Mode Enabled Flash Flash Flash De-energized Unoccupied Mode On On Off Energized Occupied, Bypass, Standby, or Tenant Off On Off Energized Override Modes Normal Operation Off On Off De-energized Adding an I/O Expansion Module (with an interconnect cable) to the main controller allows two-stage operation of the Water Source Heat Pump. IM 986 / Page 29 of 48

30 MicroTech III Controller With LonWorks Communication Module For installation and operation information on LonWorks Communication Module and other ancillary control components, see: IM MicroTech III Unit Controller for Water Source Heat Pumps (LonWorks). IM LonMaker Integration Plug-in Tool: For use with the MicroTech III Unit Controller. IM MicroTech III Wall Sensor For use with MicroTech III Unit Controller with LonWorks Monitor leaving water temperature. Relay status of all vital unit functions. Support optional control outputs. A set of three status LED's aid in diagnostics by indicating the water source heat pump operating mode and alarm conditions. If there are no current alarm conditions, the Green LED will indicate the normal unit operating mode as shown in the table below. If there are one or more alarm conditions present, various LED's will flash to indicate an alarm condition. Figure 42. LonWorks Communication Module The LonWorks communication module will plug into the MicroTech III unit controller at the CN_LON1 Header (see figure 44, page 33). Each McQuay water source heat pump can be equipped with a LonWorks communication module. The controller is microprocessor-based and is designed to communicate over a LonWorks communications network. The unit controller is factory programmed and tested with all the logic required to monitor and control the unit. The wall thermostat sets the unit mode of operation. The unit controller monitors water and air temperatures, and can communicate fault conditions to a LonWork communications network. The MicroTech III unit controller include unit-mounted return air, discharge air and leaving water temperature sensors. Options include setpoint adjustment and tenant override and the capability of substituting the return air sensor with a wall-mounted temperature sensor. Each unit controller orchestrates the following unit operations: Enable heating and cooling to maintain setpoint based on a room sensor. Enable fan and compressor operation. Monitor all equipment protection controls. MicroTech III heat pumps with a MicroTech III unit controller are LonMark certified and designed to be linked with a centralized building automation system through a LonWorks communications network for centralized scheduling and management of multiple heat pumps. Wall-mounted room sensors are available to control the heating and cooling operation of each MicroTech III Water Source Heat Pump Unit Controller. Available room sensors include: room sensor with LED status and tenant override button, room sensor with LED status, timed-override button, room sensor with LED status, timed-override button, and setpoint adjustment, and room sensor with LED status, timedoverride button, setpoint adjustment. The MicroTech III water source heat pump unit controller provides control of McQuay water source heat pumps. The controller enables the mode of operation, monitors the water and air temperatures, and indicates fault conditions. Each unit controller is factory programmed, wired, and tested for effective operation of your McQuay water source heat pump. The MicroTech III water source heat pump controller uses LonWorks technology. One of the following two versions of the application software is loaded into the controller at the factory. LonMark 3.4 certified application code is the current standard application code for MicroTech III units. Use LonMark application code in new applications including: Units that operate stand alone. Monitor discharge air temperature. Page 30 of 48 / IM 986

31 MicroTech III Controller With BACnet Communication Module for Native BACnet Communications McQuay water source heat pumps are available with a factory mounted and tested McQuay BACnet communication module The module is factory programmed and tested with all the logic required to control the unit, and is designed to communicate over a BACnet MS/TP communications network to a building automation system (BAS). The module operates the compressor, fan, and reversing valve as required to maintain the space temperature within the current setpoints. Data regarding equipment status, water and air temperatures, and fault conditions can be monitored by any BAS. Setpoints and other system preferences may be changed remotely using a front end workstation or service tool software. The module makes operational data and commands available on a communications network using BACnet objects and properties. Each heat pump controller connects to the communication network using a BACnet MS/TP communication network, which is a simple twisted-pair communications connection that operates at up to 76.8 Kbps. DIP switches on the controller enable the MS/TP MAC address to be set in the range A status LED on the unit indicates communication activity on the MS/TP communication network. Figure 43. MicroTech III BACnet Water Source Heat Pump Snap-in Communication Module Each BACnet-compliant unit includes discharge air and leaving water temperature sensors, as well as all equipment protection sensors, signals, and switches. Wall-mounted room sensors are available to control heating and cooling operation. Sensors are available for status override; wall-mounted sensors with tenant setpoint adjustment lever and timed-override button; wall-mounted sensors with LED status, timed-override button, tenant setpoint adjustment buttons, passwordprotected field service access to operational data, and optional humidity sensor; and wall-mounted sensors with LCD and programmable operation. Each BACnet-compliant controller has the following operating features: Start-up The unit will not operate until all the inputs and safety controls are checked for normal conditions. Fan operation Fan operation can be customized in software to run continuously during occupied mode, or to cycle ON or OFF appropriately on a call for heating and cooling. Cooling mode On a call for cooling, the compressor and fan start immediately. Compressor runtime is calculated as a percent of full cycle time (17 minutes) using proportional-integral control to maximize efficiency. Heating mode On a call for heating, the compressor and fan start immediately, and compressor run-time is calculated as a percent of full cycle time (17 minutes) using proportional-integral control to maximize efficiency. Short Cycle Protection and Random Start A start delay of 180 seconds plus the compressor s MAC address in seconds prevents short-cycling and simultaneous start-up. A minimum 2-minute on time and 5-minute off time for the compressor further ensures short-cycle protection. Occupied Mode A simple software control signal from the building automation system or a wallmounted unit puts the unit into occupied mode. The unit controls compressor and fan operation to maintain occupied setpoints. High and low limits for occupied setpoints are software configurable. Unoccupied Mode A simple software control signal from the building automation system or a wall-mounted unit puts the unit into unoccupied mode for night setback operation. The unit controls compressor and fan operation to maintain unoccupied heating and cooling setpoints, which are also software configurable. IM 986 / Page 31 of 48

32 After-hours Override Mode A simple software control signal from the building automation system or a wall-mounted unit can initiate after-hours heating or cooling in half-hour increments. Maximum override time is software configurable up to 9.5 hours. This feature can also be disabled in software. Reversing valve delay When the compressor turns off after heating mode, the reversing valve remains energized for 60 seconds before it returns to the normal cooling position. The reversing valve energizes 10 seconds before the compressor. Load Shed Load shedding can be orchestrated by the building automation system using the occupied/ unoccupied command in software. Brownout Protection An on-board sensor measures input voltage and suspends compressor and fan operation if the supply voltage drops below 82% of the normal line voltage for a minimum of 10 seconds, creating an alarm available in software. The alarm automatically resets when the supply voltage returns to above 90% of normal. Condensate Overflow Protection A liquid sensor at the top of the drain pan senses a high water level. Upon sensing water, cooling operation is suspended, while heating operation is allowed. The controller creates an alarm available in software. The alarm automatically resets when the water level returns to normal. Attained Temperature and Water Temperature Alarms Attained temperature, water temperature alarms with software-adjustable setpoints are available in software. The controller samples supply air and records attained temperatures for heating and cooling. If after two hours of operation, the attained temperature does not meet the software-configurable setpoint for heating or cooling as appropriate, a software alarm occurs. The alarm automatically resets when the attained temperature is within setpoints. The controller also monitors leaving water temperature. If the leaving water temperature is outside software-configurable setpoints, compressor operation is suspended and high or low water temperature alarms occur. The alarm automatically resets when the water temperature returns to within 6 deg. F of the setpoint. Unit Self-test Mode While the unit is in occupied mode, a self-test can be initiated via software. Upon initiation of the test, compressor operation is suspended for a minimum of five minutes, cooling attained temperatures are cleared, and attained temperature alarms are cleared. The unit then switches to full heat for four minutes and then records the attained supply air temperature. Compressor operation is then suspended for five minutes. The unit then switches to full cooling for four minutes and the attained supply air temperature is recorded. Attained temperature alarms are set if the attained temperatures failed to reach alarm setpoints during heating or cooling. Safety Control The unit monitors refrigerant pressure and generates separate high-pressure and lowpressure alarms available in software. While either alarm is active, compressor operation is suspended. In a refrigerant low-temperature condition, an alarm occurs and the unit operates in cooling mode for 60 seconds to defrost the heat exchanger, after which compressor operation is suspended. These alarms can be reset in software or by cycling power to the controller. Page 32 of 48 / IM 986

33 Figure 44. LonWorks Communication Module Placement on MicroTech III Unit Controller IM 986 / Page 33 of 48

34 Typical Wiring Diagram MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), PSC Motor /60Hz/1-Phase, Unit Sizes Drawing No Legend Item Description C1 Capacitor-Compressor C2 Capacitor-Fan CM Compressor - Motor COS Condensate Overflow Sensor DSC Disconnect Switch FMP Fan Motor Connector Plug FMR Fan Motor Connect Receptacle FCP Fan Connector Plug FCR Fan Connector Receptacle FSR Fan Speed Relay FSS Fan Speed Switch - Optional FS1 Fuse 1 FS2 Fuse 2 HP High Pressure Switch ISO Isolation Valve - Optional LED1 LED Annunciator / Harness LP Low Pressure Switch MIII MicroTech III Main Board MPP Main Power Connector Plug MPR Main Power Connector Receptacle OVL Compressor Overload Protector PDPG Primary Drain Pan Ground RV Reversing Valve Solenoid SOS Secondary Overflow Sensor SLTS Suction Line Temp Sensor TS1 Fan Speed Terminal Strip TS2 Thermostat Terminal Strip TSP Terminal Strip Connector Plug TSR Terminal Strip Connector Terminal X1 Transformer Table B 208V RED 230V ORG Note: Transformer: Unused wire to be capped. Page 34 of 48 / IM 986

35 Typical Wiring Diagram MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), PSC Motor /60Hz/1-Phase, Unit Sizes Drawing No Legend Item Description C1 Capacitor-Compressor C2 Capacitor-Fan CC Compressor Contactor CM Compressor - Motor DSC Disconnect Switch FMP Fan Motor Connector Plug FMR Fan Motor Connect Receptacle FCP Fan Connector Plug FCR Fan Connector Receptacle FPR Fan Power Relay FSR Fan Speed Relay FSS Fan Speed Switch - Optional FS1 Fuse 1 FS2 Fuse 2 HP High Pressure Switch ISO Isolation Valve - Optional LED1 LED Annunciator / Harness LP Low Pressure Switch MIII MicroTech III Main Board MPP Main Power Connector Plug MPR Main Power Connector Receptacle COS Condensate Overflow Sensor PDPG Primary Drain Pan Ground RV Reversing Valve Solenoid SOS Secondary Overflow Sensor SLTS Suction Line Temp Sensor TS1 Fan Speed Terminal Strip TS2 Thermostat Terminal Strip TSP Terminal Strip Connector Plug TSR Terminal Strip Connector Terminal X1 Transformer IM 986 / Page 35 of 48

36 Typical Wiring Diagram MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), X13 Motor /60Hz/1-Phase, Unit Sizes Drawing No Legend Item Description C1 Capacitor-Compressor C2 Capacitor-Fan CC Compressor Contactor CM Compressor - Motor COS Condensate Overflow Sensor DSC Disconnect Switch FMP Fan Motor Connector Plug FMR Fan Motor Connect Receptacle FCP Fan Connector Plug FCR Fan Connector Receptacle FPR Fan Power Relay FSR Fan Speed Relay FSS Fan Speed Switch - Optional FS1 Fuse 1 FS2 Fuse 2 HP High Pressure Switch ISO Isolation Valve - Optional LED1 LED Annunciator / Harness LP Low Pressure Switch MIII MicroTech III Main Board MPP Main Power Connector Plug MPR Main Power Connector Receptacle PDPG Primary Drain Pan Ground RV Reversing Valve Solenoid SOS Secondary Overflow Sensor SLTS Suction Line Temp Sensor TB3 Terminal Block TS1 Fan Speed Terminal Strip TS2 Thermostat Terminal Strip TSP Terminal Strip Connector Plug TSR Terminal Strip Connector Terminal X1 Transformer Table B 208V RED 230V ORG Note: Transformer: Unused wire to be capped. Page 36 of 48 / IM 986

37 Typical Wiring Diagram MicroTech III Unit Controller, 2-Speed Fan (Toggle or Thermostat), X13 Motor /60Hz/1-Phase, Unit Sizes Drawing No Legend Item Description C1 Capacitor-Compressor C2 Capacitor-Fan CC Compressor Contactor CM Compressor - Motor COS Condensate Overflow Sensor DSC Disconnect Switch FMP Fan Motor Connector Plug FMR Fan Motor Connect Receptacle FCP Fan Connector Plug FCR Fan Connector Receptacle FPR Fan Power Relay FSR Fan Speed Relay FSS Fan Speed Switch - Optional FS1 Fuse 1 FS2 Fuse 2 HP High Pressure Switch ISO Isolation Valve - Optional LED1 LED Annunciator / Harness LP Low Pressure Switch MIII MicroTech III Main Board MPP Main Power Connector Plug MPR Main Power Connector Receptacle PDPG Primary Drain Pan Ground RV Reversing Valve Solenoid SOS Secondary Overflow Sensor SLTS Suction Line Temp Sensor TB3 Terminal Block TS1 Fan Speed Terminal Strip TS2 Thermostat Terminal Strip TSP Terminal Strip Connector Plug TSR Terminal Strip Connector Terminal X1 Transformer IM 986 / Page 37 of 48

38 Start-up CAUTION Units must be checked for water leaks upon initial water system start-up. Water leaks may be a result of mishandling or damage during shipping. Failure by the installing contractor to check for leaks upon start-up of the water system could result in property damage. Cooling or Heating Manual Operation Adjust the thermostat heating or cooling setpoint to maintain desired space temperature. The MicroTech III unit controller has 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. Table 10 shows the LED and fault output sequences. The 24 volt low voltage terminal strip is set so R-G energizes the fan. R-W1 energizes the fan and compressor and reversing valve for heating operation. R-Y1 energizes the fan and compressor for cooling mode of 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. Table 10. LED Fault Indicators LEDs Indication Fault Yellow Green Red IMPORTANT Each water source heat pump unit has a compressor and blower motor. Each component part has and internal temperature and amperage sensitive overload. If the overload opens it will suspend unit operation. Check component parts by measuring the winding resistance and looking for an open circuit. Additional Accessories General Thermostats and Wall Sensors Easy-to-operate comfort command centers provide a complete range of deluxe features. Wall-Mounted Programmable Electronic Thermostat (P/N ) 1 Heat/1 Cool, Auto Changeover, Hardwired 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 The MicroTech III unit controller has a lockout circuit to stop compressor operation if any one of its safeties opens (high pressure or suction line sensor). If the suction line low temperature sensor 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 suction line sensor reaching its set point, or a high pressure switch. The MicroTech III unit controller has a fault output signal to an LED on a wall thermostat. Table 10 shows in which function the fault output is on (sending a signal to the LED). 7-Day, 5-2-Day Day Programmable Configurable Single-Stage Heat/Cool Systems Single-Stage Heat Pump Systems Large Display With Backlight Selectable Fahrenheit or Celsius Compatible with Gas, Oil, or Electric SimpleSet Field Programming Status Indicator Light Relay Outputs (minimum voltage drop in thermostat) Remote Sensor Compatible Ideally Suited for: Residential (New Construction/Replacement) Light Commercial Page 38 of 48 / IM 986

39 Specifications Electrical rating: 24 VAC (18-30 VAC) 1 amp maximum per terminal 3 amp maximum total load Temperature control range: 45 F to 90 F (7 C to 32 C) Accuracy: ± 1 F (± 0.5 C) System configurations: 1-stage heat, 1-stage cool, heat pump, gas, oil, electric Timing: Anti-short Cycle: 4 minutes Backlight Operation Terminations: S1, S2, Y, W/O/B, G2, G1, RC, RH, C For detailed installation, operation and application refer to Operation & Application Guide LIA303 Figure 45. Thermostat Parts Diagram - Part No Up button Down button Relay Outputs (minimum voltage drop in thermostat) Remote Sensor Compatible Ideally Suited for: Residential (New Construction/Replacement) Light Commercial Specifications Electrical rating: 24 VAC (18-30 VAC) 1 amp maximum per terminal 3 amp maximum total load Temperature control range: 45 F to 90 F (7 C to 32 C) Accuracy: ± 1 F (± 0.5 C) System configurations: 1-stage heat, 1-stage cool, heat pump, gas, oil, electric Timing: Anti-short Cycle: 4 minutes Backlight Operation Terminations: S1, S2, Y, W/O/B, G2, G1, RC, RH, C For detailed installation, operation and application refer to Operation & Application Guide LIAF014 Figure 46. Thermostat Parts Diagram - Part No Right (fan) button Left (system) button Up button Down button Field programming pins Configuration switch Reset switch RC/RH Jumper Right (fan) button Left (system) button Non-Programmable Electronic Thermostat (P/N ) 1 Heat/1 Cool, Auto Changeover, Fan Speed Control, Hardwired Fan switch Field programming pins Reset Configuration switch switch Reset switch RC/RH Jumper Configurable Single-Stage Heat/Cool Systems Single-Stage Heat Pump Systems Fan Speed Control Large Display With Backlight Selectable Fahrenheit or Celsius Compatible with Gas, Oil, or Electric SimpleSet Field Programming Status Indicator Light IM 986 / Page 39 of 48

40 Wireless Temperature Control (T9000) The T9000 Wireless Temperature Control is designed to provide precision temperature control without the installation labor and expense of wiring. Powered by AA batteries Mounts in any suitable location that will provide good temperature control. Large LCD display provides the user with current room temperature, set point temperature, time, program interval, and other system status information. For detailed installation, operation refer to Operation & Maintenance Bulletin OM 984. The second part of the T9000 system is called a Remote Control Node or RCN. An RCN interfaces with specific desired HVAC equipment, and communicates with its thermostat using unlicensed 900 MHz, radio frequency energy. At the time of installation, the T9000 thermostat is linked to one or more RCN controls. The thermostat and RCN that have been linked will not interfere with, or be affected by, any other thermostat or RCN in adjacent rooms, apartments, or neighboring homes. Remote Control Node (RCN) Used with the Wireless Temperature Control, the RCN interfaces with specific HVAC equipment, and communicates with its thermostat using unlicensed 900 MHz, radio frequency energy. Contact your local McQuay Representative for details. Programmable Non-programmable Figure 47. T9000 Overview Page 40 of 48 / IM 986

41 MicroTech III Wall-Mounted Room Temperature Sensors (P/N , , ) Figure 48. MicroTech III Wall-Mounted Room Temperature Sensors ( Not Shown) Wiring Sensors to the MicroTech III Unit Controller Figure 50. Temperature Sensor Wiring to MicroTech III Unit Controller ( , ) Temperature Sensor Terminals Sensor Sensor General MicroTech III Wall-Mounted Room Temperature Sensors provide electronic sensing of room temperatures at wall locations. All sensor models feature a thermistor (10kΩ) and a green LED for unit status. Tenant override, setpoint adjustment potentiometer, thermometer, and a communications port are optional features available in any combination This manual provides general information for the MicroTech III Wall-Mounted Room Temperature Sensors. For installation instructions refer to IM 955 Figure 49. MicroTech III Wall Sensor Details 0 to 10 K ohm Potentiometer Figure 51. Temperature Sensor Wiring to MicroTech III Unit Controller ( ) Temperature Sensor Terminals MicroTech III Unit Controller TB1 Terminals 4.59" Status LED (Green) Fan Control Slide Switch Mode Control Slide Switch Tenant Override Momentary Push Button Switch MicroTech III Unit Controller TB1 Terminals Specifications Thermistor resistance (10kΩ) (Conforms to advance thermal products curve 2) Ambient Temperature Limits: Shipping and Storage: 40 F to 160 F ( 40 C to 71 C) Operating: 40 F to 140 F (4 C to 60 C) Humidity: 5 to 95% RH, non-condensing Locations: NEMA Type 1, Indoor only Connections: Color Coded Leads IM 986 / Page 41 of 48

42 Optional Remote Sensor (P/N ) The fast, easy solution for temperature sensing problems. For tamper prone areas Poor airflow areas Troubled applications Foam gasket prevents drafts through wall opening Mounts to standard 2" x 4" outlet box 2¾"W x 4½"H Motorized Isolation Valve & Relay The motorized valve kit may be ordered as a fieldinstalled accessory. Wired as shown in Figure 52, the motorized valve will open on a call for compressor operation. Valves for unit sizes 009 to 018 are 1/2". Using a Normally Closed (N/C), power open valve, wire as illustrated in figure 52. Figure 52. Normally Closed, Power Open Motorized Valve & Relay Wiring Actuator & Valve Assembly Anti-short Bushing Anti-short Bushing 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. 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. Connector Conduit Connector Pin(s), female plug into receptacle configuration below Note: Connectors on valve must be cut off and stripped back and the wires twisted to make connections to the IV/PR Terminals Pump Restart Relay Kit P/N The MicroTech III unit controller has an internal Pump Restart Relay connected to H8, Pin 2 for the Normally Open (N/O) terminal of the internal relay. Connect to H8, Pin 1 for the Normally Closed (N/C) terminal of the internal relay. The output of the internal pump restart relay is 24- volts AC and the output is not available when the H8 connection is used to control a motorized valve. Page 42 of 48 / IM 986

43 Troubleshooting The in and outs of R-410A R-410A is a non-ozone depleting blend of two refrigerants - HFC-125 and HFC-32 in a fifty percent mixture. R-410A exhibits higher operating pressure and refrigeration capacity than R-22. R-410A is intended for use in new air conditioning applications that have traditionally been used HCFC-22 (R-22). Due to higher capacity and pressure of R-410A, it must not be used in existing R-22 systems. Although R-410A is non-flammable at ambient temperature and atmospheric pressure, it can become combustible under pressure when mixed with air. Note: R-410A should not be mixed with air under pressure for leak testing. Pressure mixtures of dry nitrogen and R-410A can be used for leak testing. Lubrication R-410A should be used only with polyester (POE) oil. The HFC refrigerant components in R-410A will not be compatible with mineral oil or alkylbenzene lubricants. R-410A systems will be charged with the OEM recommended lubricant, ready for use with R- 410A. Charging Due to the zeotropic nature of R-410A, it should be charged as a liquid. In situations where vapor is normally charged into a system, a valve should be installed in the charging line to flash the liquid to vapor while charging. Make certain that the recycle or recovery equipment used is designed for R-410A. The pressure of R-410A refrigerant is approximately 60 percent greater than that of R-22. Pressure gauges require a range up to 800 PSIG high side and 250 PSIG low side. Recovery cylinders require a 400 PSIG rating do not put R- 410A in a 300 PSIG rated cylinder. WARNING Recycle/recovery equipment must be designated for R- 410A. R-410A pressure is greater than R-22. Improper equipment can cause severe injury or death. Note: Because a water source heat pump operates under a wide range of water and air temperatures, the values printed below are to be taken as suggested pressure and temperatures. All McQuay water source heat pumps are designed for commercial use. The units are designed for the cooling mode of operation and fail safe to cooling. The reversing valve is energized for the heating mode of operation. Superheat Head Pressure Water Delta T 8 to 14 degrees PSIG 10 to 14 All information above is based on ISO standard and tested at these conditions. General Maintenance 1. Normal maintenance on all units is generally limited to filter changes. Units are provided with permanently lubricated motors and require no oiling even though oil caps may be provided. 2. Filter changes are required at regular intervals. The time period between changes will depend upon the project requirements. Some applications such as motels produce a lot of lint from carpeting and linen changes, and will require more frequent filter changes. Check filters at 60-day intervals for the first year until experience is acquired. If light cannot be seen through the filter when held up to sunlight or a bright light, it should be changed. A more critical standard may be desirable. 3. The condensate drain pan should be checked annually and cleaned and flushed as required. 4. Record performance measurements of volts, amps, and water temperature differences (both heating and cooling). A comparison of logged data with start-up and other annual data is useful as an indicator of general equipment condition. 5. Periodic lockouts almost always are caused by air or water problems. The lockout (shutdown) of the unit is a normal protective result. Check for dirt in the water system, water flow rates, water temperatures, airflow rates (may be a dirty filter), and air temperatures. If the lockout occurs in the morning following a return from night setback, entering air below machine limits may be the cause. IM 986 / Page 43 of 48

44 Troubleshooting Refrigeration Circuit Head Suction Compressor Super Symptom Pressure Pressure Amp Draw Heat Subcooling Air Water Safety Temp (loops) Temp Lock Differential Differential Out Charge Undercharge System Low Low Low High Low Low Low Low Pressure (Possible Leak) Overcharge System High High High Normal High Normal Low Normal High Pressure Low Air Flow Heating High High High High Normal Low High Low High Pressure Low Air Flow Cooling Low Low Low Low Normal High High Low Low Temp Low Water Flow Heating Low Low Normal Normal Low Low High Low High Low Temp Low Water Flow Cooling High High High High Low Low High High Pressure High Air Flow Heating Low Low Low Low High Low Low Low Temp High Air Flow Cooling Low High Normal High Low Low Normal High Pressure High Water Flow Heating Normal Low Normal High Normal Normal Low High Pressure High Water Flow Cooling Low Low Low Low High Normal Low Low Temp TXV Restricted High Low Normal Low High High Low Low Figure 53. Cooling Mode Figure 54. Heating Mode Coil Air to Refrigerant Heat Exchanger Return Air Thermal Expansion Valve Coaxial Heat Exchanger Water In Water Out Coil Air to Refrigerant Heat Exchanger Return Air Thermal Expansion Valve Coaxial Heat Exchanger Water In Water Out Sensing Bulb and Capillary Tube Compressor Sensing Bulb and Capillary Tube Compressor Blower Blower Reversing Valve Reversing Valve Conditioned Air (Cooling) Conditioned Air (Heating) Cooling Refrigeration Cycle When the wall thermostat is calling for COOLING, the reversing valve directs the flow of the refrigerant, a hot gas, leaving the compressor, to the water-to-refrigerant heat exchanger. Here the heat is removed by the water and the hot gas condenses to become a liquid. The liquid then flows through a thermal expansion metering system to the air-torefrigerant heat exchanger coil. The liquid then evaporates becoming a gas, at the same time absorbing heat and cooling the air passing over the surfaces of the coil. The refrigerant then flows as a low pressure gas through the reversing valve and back to the suction side of the compressor to complete the cycle. Heating Refrigeration Cycle When the wall thermostat is calling for HEATING, the reversing valve directs the flow of the refrigerant, a hot gas, leaving the compressor, to the air-to-refrigerant heat exchanger coil. Here the heat is removed by the air passing over the surfaces of the coil and the hot gas condenses to become a liquid. The liquid then flows through a capillary thermal expansion metering system to the water-to-refrigerant heat exchanger. The liquid then evaporates becoming a gas, at the same time absorbing heat and cooling the water. The refrigerant then flows as a low pressure gas through the reversing valve and back to the suction side of the compressor to complete the cycle. Page 44 of 48 / IM 986

45 Troubleshooting the Water Source Heat Pump Unit Figure 55. Troubleshooting Guide - Unit Operation Low voltage, check power supply voltage Fuse may be blown, circuit breaker is open Wire may be loose or broken. Replace or tighten wires Unit control, check thermostat for correct wiring or faulty thermostat Check wiring - loose or broken and check for faulty connection Check capacitor Check relays and contacts, also capacitor and wiring Check high pressure switch, low pressure switch and low temperature switch to see if unit is cycling on the safety Check to see if the reversing valve is not hung up and is operating correctly Check condensate overflow switch in cool mode of operation Check thermostat for proper location Compressor runs in short cycle Neither fan, nor compressor runs and all LED lights are off Unit Fan operates, compressor does not Check wiring - loose or broken and check for bad connection High or Low pressure lockout A. Cool mode, check water flow B. Heating mode, check air flow C. Check reversing valve for proper valve position Check compressor overload - make sure it is closed Check compressor to ground, or for internal short to ground Compressor winding may be open. Check continuity with ohm meter Compressor attempts to start but does not Insufficient cooling or heating Check compressor wiring for defective wiring or loose connection Check for defective compressor internal windings with ohm meter Check for faulty compressor capacitor Check for lock rotor amp draw Check thermostat for improper location Check for proper air flow - filter could be dirty Check blower assembly for dirt or faulty fan motor capacity Check for low refrigerant charge Check amp draw on blower assembly Check for proper water flow and delta T ( F) IM 986 / Page 45 of 48

46 Troubleshooting the MicroTech III Unit Controller Figure 56. MicroTech III Unit Controller LED Status and Faults Troubleshooting Reference DANGER To avoid electrical shock, personal injury or death, be sure that field wiring complies with local and national fire, safety, and electrical codes, and voltage to the system is within the limits shown in the job-specific drawings and unit electrical data plate(s). Power supply to unit must be disconnected when making field connections. To avoid electrical shock, personal injury or death, be sure to rigorously adhere to field wiring procedures regarding proper lockout and tagout of components. General Use and Information The MicroTech III unit controller is provided with two drive terminals, R(24VAC) and C(0 VAC) that can be used by the end user to drive the thermostat inputs (G, Y1, Y2, W1, and W2) and control inputs (U, E, and O). Any combination of a single board drive terminal (R or C) may be used to operate the MicroTech III unit controller s control or thermostat inputs. However, only one drive terminal (R or C) can be connected to any individual input terminal or damage may result. Some control inputs are not accessible to the end user (for example, HP, LP, SLTS, and COF). Typically the MicroTech III unit controller 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 MicroTech III unit controller 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 MicroTech III unit controller 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 the MicroTech III unit controller inputs. No outside power source may be used to operate the MicroTech III unit controller inputs. Yes Yes Yes Yes Yes Yes Yes Yes Read Outputs Check Timers Brownout No High Pressure No Low Pressure No Low Suct Temp Sensor No Low Suct Temp No Room Temp Sensor Failure No R - W 1 R -Y 1 Condensate Overflow No No Stop Compressor Flash Green LED Stop Compressor Flash Red LED Stop Compressor Flash Yellow LED Flash Green LED Solid Red LED Stop Compressor No Heating Mode Yes Flash Yellow LED Run in Cooling Mode for 1 Min. No Cooling Mode Yes Turn on Yellow LED Start Compressor 30 Second Time Delay Request for Water Flow Stop Compressor Reversing Valve On Time Delay Page 46 of 48 / IM 986

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48 McQuay Training and Development Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority. For training information on all McQuay HVAC products, please visit us at and click on training, or call and ask for the Training Department. Warranty All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product Warranty. Consult your local McQuay Representative for warranty details. Refer to Form Y. To find your local McQuay Representative, go to This document contains the most current product information as of this printing. For the most up-to-date product information, please go to Products Manufactured in an ISO Certified Facility McQuay International IM 986 / Page 48 of 48