SmartSource Single Stage Horizontal & Vertical Water Source Heat Pumps

Transcription

1 Installation & Maintenance Data IM 1139 Group: WSHP Part Number: Date: March 2012 SmartSource Single Stage Horizontal & Vertical Water Source Heat Pumps Model GSH - Horizontal Unit Model GSV - Vertical Unit Sizes McQuay International

2 Contents Nomenclature...3 General Information...5 Safety, Receiving and Storage...5 Installation Considerations...5 Physical Data...6 Vertical Units...6 Horizontal Units...7 Installation GSH Horizontal Unit...8 Service Clearances...8 Procedure...8 Installation Considerations...9 Filter Access...9 Discharge Air Conversion...9 Ductwork & Attenuation...11 Discharge Duct Dimensions...12 Return Air Filter Rack Assembly & Duct Collar Connections...13 Ventilation Air...13 Installation GSV Vertical Unit...14 Service Clearances...14 Procedure...14 Ductwork and Attenuation...15 Discharge Duct Collar Dimensions...15 General...15 Piping & Electrical Connections Locations...17 Return Air Filter Rack Assembly & Duct Collar Connections...17 System Applications...18 Water Loop Application...18 Ground-Loop Application...19 Ground-Water Application...21 Water System Quality...23 Supply & Return Piping...24 Condensate Drain Connection...25 Cleaning & Flushing System...26 Controls...27 MicroTech III SmartSource Unit Controller...29 Unit Protections & LED Fault Status Annunciation...29 MicroTech SmartSource Controller with LonWorks Communication Module...31 MicroTech SmartSource Controller with BACnet Communication Module...31 Rotary Fan Speed Selection Switch...33 Constant Torque Motor...33 Constant CFM Type ECM Motor Fan Settings...34 Information for Initial Start-up...35 Check, Test & Start Procedure...35 Start-up...35 Operating Limits...36 Environment...36 Factory-Installed Option...36 Motorized Isolation Valve & Relay...36 Typical Wiring Diagrams...37 MicroTech III Unit Control with BACnet Communication Module (HGRH) V, 1-Phase...37 MicroTech III Unit Control with BACnet Communication Module (HGRH) V, 1-Phase, Service & Disconnect...38 MicroTech III Unit Control with BACnet Communication Module (WSE & DSH) V, 1-Phase with 115V Loop Pumps and 20kW Electric Heat...39 MicroTech III Unit Control with BACnet Communication Module (WSE & DSH) Service & Disconnect V, 1-Phase with 115V Loop Pumps and 20kW Electric Heat.40 MicroTech III Unit Control with LonWorks Communication Module V, 3-Phase with 230V Loop Pumps and 5kW Electric Heat...41 MicroTech III Unit Control with LonWorks Communication Module Service & Disconnect V, 3-Phase with 230V Loop Pumps and 5kW Electric Heat...42 MicroTech III Unit Control with BACnet Communication Module (WSE) - 460V, 3-Phase with 230V Loop Pumps and 20kW Electric Heat...43 MicroTech III Unit Control with BACnet Communication Module (WSE) Service & Disconnect - 460V, 3-Phase with 230V Loop Pumps and 20kW Electric Heat...44 Maintenance...45 General Maintenance...45 The in and outs of R-410A...45 Lubrication...45 Charging...45 Troubleshooting...46 Cooling Refrigeration Cycle...46 Heating Refrigeration Cycle...47 Water Source Heat Pump Equipment Check, Test and Start Form...48 Unit Check / Equipment Data...49 Commercial Check, Test and Start Worksheet...50 Page 2 of 52 / IM 1139

3 Nomenclature Note: Text displayed in Bold-Italics designate standard offering. Category Code Item Code Option Code Designation & Description (Bold-Italic = Standard) Product Category 1 1 W = Water Source Heat Pump Model Type GS = High Efficiency Single Stage Configuration 3 4 H = Horizontal V = Vertical Nominal Capacity = 7,000 Btuh Nominal Cooling 009 = 9,000 Btuh Nominal Cooling 012 = 12,000 Btuh Nominal Cooling 015 = 15,000 Btuh Nominal Cooling 019 = 19,000 Btuh Nominal Cooling 024 = 24,000 Btuh Nominal Cooling 030 = 30,000 Btuh Nominal Cooling 036 = 36,000 Btuh Nominal Cooling 042 = 42,000 Btuh Nominal Cooling 048 = 48,000 Btuh Nominal Cooling 060 = 60,000 Btuh Nominal Cooling 070 = 70,000 Btuh Nominal Cooling Unit Control 5 8 B = MicroTech III Unit Controller Design Series (Vintage) = Revision / Design Series 1 Voltage 7 10 A = 115/60/1 E = /60/1 F = /60/3 J = /60/1 K = 460/60/3 Range for Entering Water/Glycol Temp GW = Ground Water WL = Water Loop GL = Ground Loop Return Air Location 9 13 L = Left-Hand Return Air & Right-Hand Piping R = Right-Hand Return Air & Right-Hand Piping Discharge Air Location E = End (Horizontal Unit Only) T = Top (Vertical Unit Only) S = Straight (Horizontal Unit Only) Fan Motor = ECM Constant CFM 5 = ECM Constant Torque Dehumidification Option B = Hot Gas Reheat Smart Dehumidification C = Simplified Dehumidification (Lower CFM no HGRH or no Humidistat) D = Humidistat Controlled Dehumidification (No HGRH) E = Humidistat Only Y = None Sound Package Y = None A = Premium Coaxial Heat Exchanger Construction C = Copper Inner Tube - Steel Outer Tube (Supply Liquid / Refrigerant) S = Cupronickel Inner Tube - Steel Outer Tube Primary Air Coil Option S = Standard E = E-Coated Communication Module B = BACnet L = LonWorks Y = None Filter Rack = 4-Sided, 2" w/duct Collar & Door 3 = 4-Sided, 2" w/duct Collar, Door, Hi-Merv Seal 4 = 4-Sided, 4" w/duct Collar, Door, Hi-Merv Seal Y = None Filter Type A = Disposable E = Merv 8 Factory-Installed G = Merv 13 (4-inch thick) Factory-Installed Y = None Water Coil - Indoor Air E = Waterside Economizer Y = None Electric Heating - Indoor Air C = 5.0 kw Internal Electric Heater E = 10.0 kw Internal Electric Heater F = 15.0 kw Internal Two Stage Electric Heater G = 20.0 kw Internal Two Stage Electric Heater P = Control for Electric Heat, Single 24V Signal (Field-installed Duct Heater by others) Y = None IM 1139 / Page 3 of 52

4 Model Nomenclature Category Code Item Code Option Code Designation & Description (Bold-Italic = Standard) Control Secondary Heat Type B = Boilerlerss Electric Heat E = Emergency Electric Heat P = Primary Electric Heat (No Heat Pump Heating) S = Supplemental Heat Y = None Desuperheater (Hot Water Generator) D = Desuperheater Y = None Loop Pump S = One Low Head 230 Volt Pump, Grundfos UP26-99F 1L = One High Head 230 Volt Pump, Grundfos UP26-116F 2S = Two Low Head 230 Volt Pumps, Grundfos UP26-99F 2L = Two High Head 230 Volt Pumps, Grundfos UP26-116F 3S = One Low Head 115 Volt Pump, Grundfos UP26-99F 4S = Two Low Head 115 Volt Pumps, Grundfos UP26-99F YY = None Coaxial Coil Supply Liquid B = 2-Way, Motorized - 24v Valve Control, NO Flow Control Y = None Coaxial Coil Supply Liquid G = Auto Flow Control 5.0 GPM Flow Control H = Auto Flow Control 6.0 GPM I = Auto Flow Control 8.0 GPM J = Auto Flow Control 9.0 GPM K = Auto Flow Control 10.0 GPM L = Auto Flow Control 11.0 GPM M = Auto Flow Control 12.0 GPM N = Auto Flow Control 13.0 GPM P = Auto Flow Control 15.0 GPM S = Auto Flow Control 18.0 GPM Y = None Desuperheater Water Flow Options Q = Pump /60/1 Voltage Y = None Water Coil Piping Package Options A = 3-Way Motorized - 24V Valve Control, NO to Coax (Hot Water or Waterside Economizer Primary Drain Pan Material S - Stainless Steel Compressor Insulation B = Compressor Insulation Sound Blanket Y = None Compressor Isolation B = Isolated base Insulation A = 1/2" Fiberglass Skin-Faced Compressor Compartment B = 1/2" Fiberglass - Foil Faced C = 3/8" Closed Cell Foam Insulation - Air Side A = 1/2" Fiberglass Skin-Faced B = 1/2" Fiberglass - Foil-Faced C = 3/8" Closed Cell Foam Insulation - Piping A = Insulated Piping Y = None Cabinet Finish A = Powder Coat Y = None Cabinet Color Y = None W = Off White T = Textured Charcoal Bronze Fan Motor Control C = Various Speeds with 4 Adjustment Settings Disconnect Switch Y = None N = Non-Fused Control Transformer = 50VA Control Transformer 2 = 75VA Control Transformer Thermostat/Sensor Control T = Thermostat Control S = Sensor Control Expansion Device A = Thermal Expansion Valve Thermal Bulb and Equalizer Tube Alarm Relay A = Alarm Relay (Dry Contacts) Y = None Extended Warranty, Parts Only YY = None 1E = 1-Year, Entire Unit Parts Only 2C = 2-Year Parts (Compressor Only) 2R = 2-Year Parts (Refrigerant Circuit) 3C = 3-Year Parts (Compressor Only) 3R = 3-Year Parts (Refrigerant Circuit) 4C = 4-Year Parts (Compressor Only) 4R = 4-Year Parts (Refrigerant Circuit) Page 4 of 52 / IM 1139

5 General Information Safety, Receiving and Storage CAUTION Sharp edges can cause personal injury. 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, immediately open the cartons to check for concealed damage. If any damage is found, notify the carrier within 48 hours to establish your claim and request their inspection and a report. The Warranty Claims Department should then be contacted. Do not stand or transport the machines on end. For storing, each carton is marked with up arrows. In the event that elevator transfer makes up-ended positioning unavoidable, do not operate the machine until it has been in the normal upright position for at least 24 hours. 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. 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. Installation Considerations 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. 1. To prevent damage, do not operate this equipment for supplementary heating and cooling during the construction period. 2. Inspect the carton for any specific tagging numbers indicated by the factory per a request from the installing contractor. Note: 1. Check the unit data plate for correct voltage, phase and capacity with the plans before installing the equipment. Also, make sure all electrical ground connections are made in accordance with local code. 2. ECM motors on 460/60/3 volt units require a 265 volt power supply. Both a hot AND a neutral wire are required to obtain proper fan motor voltage. Therefore, 4-wires with a wye type wiring arrangement is required. 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 ceiling height versus the height 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. 7. 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. If plastic film is not available, the shipping carton may be modified to cover the units during construction. 8. Remove the Styrofoam shipping block under the fan housing on horizontal units before start-up. Figure 1: Horizontal unit foam shipping block Remove foam shipping block IM 1139 / Page 5 of 52

6 Physical Data Vertical Units Table 1: Unit sizes 007 through 030 Description Unit Sizes 007 through Compressor Type Rotary Rotary Rotary Rotary Rotary Scroll Scroll Refrigeration Charge (Oz.) Fan Wheel (D x W) 6" x 8" 6" x 8" 6" x 8" 9" x 7" 9" x 7" 9" x 7" 9" x 7" Fan Motor HP 1/10 1/10 1/10 1/3 1/3 1/3 1/2 Water Connection Size (FPT) 1/2" 1/2" 1/2" 3/4" 3/4" 3/4" 3/4" Desuperheater Connection Size (FPT) Coax & Water Piping Volume 70ºF) 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Condensate Connection Size (FPT) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 Air Coil Face Area (Sq Ft.) Air Coil Dimensions (W x H) 18" x 17" 18" x 17" 18" x 17" 18" x 20" 18" x 20" 28" x 20.5" 28" x 20.5" Air Coil Rows Air Coil Tube Size 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" Filter Size 17.5" x 20.0" 17.5" x 20.0" 17.5" x 20.0" 18.0" x 20.0" 18.0" x 20.0" 27.8" x 22.1" 27.8" x 22.1" Operating Weight Shipping Weight Table 2: Unit sizes 036 through 070 Unit Sizes 036 through 070 Description Compressor Type Scroll Scroll Scroll Scroll Scroll Refrigeration Charge (Oz.) Fan Wheel (D x W) 11" x 10" 11" x 10" 11" x 10" 11" x 10" 11" x 10" Fan Motor HP 1/2 3/4 3/4 1 1 Water Connection Size (FPT) 3/4" 1" 1" 1" 1" Desuperheater Connection Size (FPT) 1/2" 1/2" 1/2" 1/2" 1/2" Coax & Water Piping Volume 70ºF) Condensate Connection Size (FPT) 3/4 3/4 3/4 3/4 3/4 Air Coil Face Area (Sq Ft.) Air Coil Dimensions (W x H) 26" x 27" 30" x 27" 30" x 27" 34" x 27" 34" x 27" Air Coil Rows Air Coil Tube Size 3/8" 3/8" 3/8" 3/8" 3/8" Filter Size 28.9" x 25.9" 28.9" x 29.9" 28.9" x 29.9" 33.9" x 29.9" 33.9" x 29.9" Operating Weight Shipping Weight Page 6 of 52 / IM 1139

7 Horizontal Units Table 3: Unit sizes 007 through 030 Description Unit Sizes 007 through 030 Physical Data Compressor Type Rotary Rotary Rotary Rotary Rotary Scroll Scroll Refrigeration Charge (Oz.) Fan Wheel (D x W) 6" x 8" 6" x 8" 6" x 8" 9" x 7" 9" x 7" 9" x 7" 9" x 7" Fan Motor HP 1/10 1/10 1/10 1/3 1/3 1/3 1/2 Water Connection Size (FPT) 1/2" 1/2" 1/2" 3/4" 3/4" 3/4" 3/4" Desuperheater Connection Size (FPT) 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Coax & Water Piping Volume 70ºF) Condensate Connection Size (FPT) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 Air Coil Face Area (Sq Ft.) Air Coil Dimensions (W x H) 16" x 17" 16" x 17" 16" x 17" 18" x 20" 18" x 20" 18" x 32.5" 18" x 32.5" Air Coil Rows Air Coil Tube Size 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" Filter Size 15.5" x 20.0" 15.5" x 20.0" 15.5" x 20.0" 18.0" x 20.0" 18.0" x 20.0" 16.75" x 34" 16.75" x 34" Operating Weight Shipping Weight Table 4: Unit sizes 036 through 070 Description Unit Sizes 036 through Compressor Type Scroll Scroll Scroll Scroll Scroll Refrigeration Charge (Oz.) Fan Wheel (D x W) 11" x 10" 11" x 10" 11" x 10" 11" x 10" 11" x 10" Fan Motor HP 1/2 3/4 3/4 1 1 Water Connection Size (FPT) 3/4" 1" 1" 1" 1" Desuperheater Connection Size (FPT) 1/2" 1/2" 1/2" 1/2" 1/2" Coax & Water Piping Volume 70ºF) Condensate Connection Size (FPT) 3/4 3/4 3/4 3/4 3/4 Air Coil Face Area (Sq Ft.) Air Coil Dimensions (W x H) 26" x 27" 30" x 27" 30" x 27" 34" x 27" 34" x 27" Air Coil Rows Air Coil Tube Size 3/8" 3/8" 3/8" 3/8" 3/8" Filter Size 18.75" x 37.25" 18.75" x 42.62" 18.75" x 42.62" 18.75" x 48" 18.75" x 48" Operating Weight Shipping Weight Table 5: Horizontal unit corner weights, percentage of total operating weight (Base unit only) Unit Size Total Operating Weight (lbs.) Corner Weight % of Total Operating Weight A B C D 30% 20% 20% 30% C B D Water Connections Compressor Control Box Unit Front A IM 1139 / Page 7 of 52

8 Installation GSH Horizontal Unit Service Clearances Figure 2: Recommended minimum & optimum unit clearances Procedure 1. Locate the unit in an area that allows for easy removal of the filter and access panels. Leave the recommended amount of clearance around the heat pump for easy removal, and to perform routine maintenance, or troubleshooting, refer to Figure 2. Provide sufficient room to make water, electrical and duct connections. 2. The contractor should make sure that adequate ceiling panel access exists, including clearance for hanger brackets, duct collars and fittings at water and electrical connections. 3. Allow adequate room below the unit for a condensate trap and do not locate the unit above pipes. 4. Each unit is suspended from the ceiling by four threaded rods. The rods are attached to the unit corners by a hanger bracket through a rubber isolator. 6. When attaching the hanger rods to the unit, a double nut is recommended since vibration could loosen a single nut. The installer is responsible for providing the hex nuts when installing hanger rods. Refer to Figure 6 on page Leave minimum 3" (76 mm) extra threaded rod below the double nuts or minimum 3" (76 mm) clearance between top of unit and ceiling above to facilitate top panel removal for servicing. Figure 3: Typical horizontal unit installation CAUTION Do not use rods smaller than shown in Figure 6 on page 9. The rods must be securely anchored to the ceiling or to the bar joists. 5. Each unit is furnished with a hanger kit. The kit is shipped un-assembled and includes hanger brackets, rubber isolators, washers, bolts and lock washers. Lay out the threaded rods per the dimensions in Figure 5 on page 9. Page 8 of 52 / IM 1139

9 Installation GSH Horizontal Unit Installation Considerations Filter Access Each unit is shipped with a filter bracket for side filter removal. For opposite side filter removal the filter rack assembly may be turned 180 degrees. Also, a sheet metal duct filter retainer can be fabricated when return air duct work is used. Figure 4: Filter rack filter door removal Figure 7: Heavy-duty hanger brackets (sizes ) 3/8" Threaded Rod (By Others) Heavy-Duty Bracket Vibration Isolator Bolt & Lock Washer Hex Nuts (Double) (By Others) Filter rack Filter access door Figure 5: Hanger bracket locations - sizes X Table 6: Hanger bracket location dimensions W Unit Size W X Y Threaded access door knobs 007, 009, (1135) (599) (485) 015, (1272) (620) (505) 024, (1579) (607) (474) " (1833) 27" (686) 21.24" (539) 042, " (1970) 27" (686) 21.24" (539) 060, " (2107) 27" (686) 21.24" (539) Note: All dimensions within ± 0.10 inches (2.5 mm). Figure 6: Hanger bracket details (sizes ) Y Horizontal unit sizes 024 through 070 are provided with heavy-duty hanger brackets, fastening bolts, vibration isolators and washers. Do not subsitute these brackets for others, for unit sizes 024 through /8" threaded rods and hex nuts (doubled) are provided by others. Discharge Air Conversion A straight discharge unit may be converted to an end discharge by doing the following: Note: The information covered in this section of the blower assembly orientation is typical of Daikin McQuay units. Regardless, if you are changing end to straight or straight to end the blower assembly has to turn 90 degrees and simultaneously rotate 180 degrees to achieve the proper orientation. Not all Daikin McQuay units will have the same air discharge location but will have the same general results when following the instructions. Hazardous Voltage! DANGER Disconnect all electric power including remote disconnects before servicing. Failure to disconnect power before servicing can cause severe personal injury or death. CAUTION Sharp edges can cause personal injury. Avoid contact with them. Bolt & Lock Washer 3/8" Threaded Rod (By Others) Vibration Isolator Washer Hex Nuts (Double) (By Others) 1. Turn off power to the unit at the breaker box. 2. Remove the top panel by removing the screws around the perimeter of the top securing it to the lower cabinet (Figure 8). Note: Retain all screws for reinstalling. 3. Remove the access panel to the fan motor by loosening the two (2) screws at the bottom holding the panel (Figure 8). Remove the piece of insulation at the bottom on the side of the bottom panel. IM 1139 / Page 9 of 52

10 Installation GSH Horizontal Unit Figure 8: Remove top and access panel to fan motor Remove Top Remove screws around the perimeter of top Remove Access Panel to Fan Assembly Remove two (2) screws at bottom of access panel to access fan motor Fan Discharge Panel Assembly (Bottom-Horizontal Orientation) 4. Remove the screws securing the fan discharge panel assembly (Figure 8). 5. Lift the fan assembly out rotating it 180 degrees and position it within the opening at the end of the unit (Figure 9). With the fan motor in the end discharge position the fan and housing orientation is top-horizontal. In a straight air discharge arrangement the housing is in the bottom-horizontal orientation. 6. Secure the fan assembly to the unit frame with the screws removed previously. 7. Reinstall the access panel in the fan motor access opening (Figure 10). 8. Reinstall the top panel and secure with screws removed previously. Note: If installed correctly the fan motor should be accessible when the fan motor access panel is removed. Figure 9: Lift out the fan assembly, turn 90 degrees and rotate 180 degrees Rotate the Fan Assembly 180 degrees End Discharge Arrangement (Top-Horizontal) Orientation Position the fan assembly in the end opening with the fan in the tophorizontal orientation Straight Discharge Arrangement (Bottom-Horizontal) Orientation Remove screws securing the fan assembly to the cabinet. Note bottom-horizontal orientation of fan assembly Page 10 of 52 / IM 1139

11 Installation GSH Horizontal Unit Figure 10: Reinstall the top and access panel Reinstall Top Reinstall Access Panel to Fan Motor Ductwork & Attenuation Discharge ductwork is normally used with these conditioners. Return air ductwork may also be required. All ductwork should conform to industry standards of good practice as described in the ASHRAE Systems Guide. The discharge duct system will normally consist of: a flexible connector at the unit a 10 ft. length of insulted duct and a trunk duct teeing into a branch duct with discharge diffusers as shown in Figure 11. With metal duct material, the entire branch duct should be internally lined with acoustic fibrous insulation for sound attenuation. Glass fiber duct board material is more absorbing and may permit omission of the flexible boot connector. As a general recommendation, the acoustic fibrous insulation should be at least 1/2 inch thick over the entire duct run (Figure 11). For better sound attenuation, line the last five diameters of duct before each register with a one-inch thick sound blanket. Elbows, tees and dampers can create turbulence or distortion in the airflow. Place a straight length of duct, 5 to 10 times the duct width, before the next fitting to smooth out airflow. Diffusers that are located in the bottom of a trunk duct can also produce noise. For this same reason, volume control dampers should be located several duct widths upstream from an air outlet. For Hotel, Motel, Dormitory or Nursing Home applications that use a single duct discharge, a velocity of 500 to 600 fpm is suggested. These applications typically have static pressures as low as 0.05 inches of water and duct lengths approximately six feet in length. The discharge duct must be fully lined and have a square elbow without turning vanes. Return air for these applications should enter through a low sidewall filter grille and route up the stud space to a ceiling plenum. For horizontal heat pumps mounted from the ceiling, an insulated return plenum is sometimes placed at the return air opening to further attenuate line-of-sight sound transmission through return openings. Figure 11: Typical ducting of horizontal unit Acoustically Insulated Return Air Duct Trunk Duct Room Air Supply Diffuser Flexible (Boot) Connector Acoustically Insulated Duct (approximately 10') Trunk Duct Tee Branch Duct Branch Duct Room Air Supply Diffuser Room Air Supply Diffuser IM 1139 / Page 11 of 52

12 Installation GSH Horizontal Unit Discharge Duct Dimensions Figure 12: GSH discharge duct collar locations P P FM AP O R Q G Left Return - End Discharge O R G Q Right Return - End Discharge FM AP FM AP Front O O Front N N Left Return - Straight Discharge View P M M P Right Return - Straight Discharge View Legend: FM AP = Fan Motor Access Panel Table 7: GSH discharge duct collar dimensions GSH Horizontal Unit M Discharge Air Duct Connection in inches (mm) N R O P Q Left-hand Right-hand Left-hand Right-hand 007, 009, (157) 8.23 (209) 4.10 (104) 4.89 (124) 9.45 (240) 6.12 (156) 4.10 (104) 8.23 (209) 015, (118) 5.75 (146) 3.15 (80) (266) 9.33 (237) 4.63 (118) 3.15 (80) 5.75 (146) 024, (112) 6.20 (157) 2.71 (69) (264) 9.32 (237) 4.41 (112) 2.71 (69) 6.20 (157) (124) 4.74 (120) 2.81 (71) (349) (337) 4.88 (124) 2.81 (71) 4.74 (120) 042, (124) 4.74 (120) 2.81 (71) (349) (337) 4.88 (124) 2.81 (71) 4.74 (120) 060, (124) 4.74 (120) 2.81 (71) (349) (337) 4.88 (124) 2.81 (71) 4.74 (120) Note: All duct dimensions are referenced from the outside edge of the flange. Table 8: GSH piping & electrical connections dimensions GSH Horizontal Unit D Supply Piping Connections in inches (mm) E Return F G Condensate Drain 3/4" FPT H Electrical Connections in inches (mm) J K L Low Voltage 4 Between Line Voltage 5 007, 009, (67) 5.65 (144) 1.47 (37) 3.76 (96) 1.98 (50) 2.08 (53) 7.06 (179) 9.14 (232) 015, (75) 5.95 (151) 1.47 (37) 4.07 (103) 1.98 (50) 2.08 (53) 7.06 (179) 9.14 (232) 024, (66) (340) 1.57 (40) 4.29 (109) 1.94 (49) 2.57 (65) 7.36 (187) 9.93 (252) (70) (345) 1.57 (40) 4.36 (111) 1.94 (49) 3.57 (91) 8.23 (209) (300) 042, (78) (353) 1.57 (40) 4.36 (111) 1.94 (49) 3.57 (91) 8.23 (209) (300) 060, (78) (353) 1.57 (40) 4.36 (111) 1.94 (49) 3.57 (91) 8.23 (209) (300) Notes: 1 Supply and return piping connections = 1/2" (13 mm) FPT. 2 Supply and return piping connections = 3/4" (19 mm) FPT. 3 Supply and return piping connections = 1" (25.4 mm) FPT. 4 Low voltage opening = 7/8" (22 mm) diameter. 5 Line voltage opening = 1-1/8" (29 mm) diameter. Page 12 of 52 / IM 1139

13 Installation GSH Horizontal Unit Figure 13: GSH piping & electrical connections locations Line Voltage (Note 4, page 12 ) Low Voltage (Note 3, page 12) L K J H C AP Front View Legend: C AP = Control Access Panel Figure 14: Unit with optional disconnect switch F Line voltage hole in disconnect switch Disconnect switch D (Note 1, page 12) E Return Air Filter Rack Assembly & Duct Collar Connections Return air ductwork can be connected to the standard filter rack, see Figure 15. The unit comes standard with a 2" (51mm) thick factory-installed throwaway filter, mounted in a 4-sided combination filter rack and return air duct collar. Filters can be easily removed from either side by interchanging the removable filter door to the right or left side and rotating the filter rack assembly 180 degrees. 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 hit the drain pan or the air coil. Ventilation Air Ventilation may require outside air. The temperature of the ventilation air must be controlled so that mixture of outside air and return air entering the conditioner does not exceed conditioner application limits. It is also typical 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 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 36. Figure 15: GSH return air duct collar location.839" (21.3 mm).839" (21.3 mm) Z H 2.125" (54 mm).839" (21.3 mm) Z W * 2.10" (53 mm) See Note.839" (21.3 mm).839" (21.3 mm) Table 9: GSH return air duct collar dimensions Unit Size Z W Z H 007, 009, (538) (395) 015, (611) (461) 024, (435) (872) " (486) 37.6" (955) 042, " (486) (1067) 060, " (486) (1229) Note: * Optional 4" filter rack = 4.10" (104 mm). IM 1139 / Page 13 of 52

14 Installation GSV Vertical Unit Service Clearances Figure 16: Recommended clearances for service access Procedure 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. Make sure that sufficient access has been provided for installing and removing the unit, including clearance for duct collars and fittings at water and electrical connections. 3. Allow adequate room around the unit for a condensate piping. 4. The unit can be installed free standing in an equipment room. However, closet installations are more common for small vertical type units. Generally, the unit is located in the corner of a closet with the non-ducted return air facing 90 degrees to the door and the major access panels facing the door as in Figure 17. Alternatively, the unit can have a ducted return air with the opening facing the door and the major access panels facing 90 degrees to the door. 5. Unit must be located on top of a vibration absorbing material such as a rubber (isolation pad) that is the same size as the base of the unit, to minimize vibration and noise (Figure 17). Page 14 of 52 / IM 1139 Figure 17: Vertical unit - typical installation in small mechanical room or closet

15 Installation GSV Vertical Unit 1 - Supply Air Ducting 2 - Acoustical Thermal Lining (10 ft.) 3 - Line Voltage - 7/8" (22 mm) Hole 4 - Low Voltage - 7/8" (22 mm) Hole 5 - Flexible Duct Collar 6 - Louvered Door for Return Air 7 - Condensate Drain Connection 8 - Flexible Return Hose with Flow Controller/Ball Valve (3/4" FPT) 9 - Flexible Supply Hose with Y-Strainer/Ball Valve (3/4" FPT) 10 - Access Panel to Controller 11 - LED Annunciator Status Lights 12 - Vibration Isolation Pad Ductwork and Attenuation Discharge ductwork is normally used with these units. Where return air ductwork is required, the unit comes standard with a 2" (51mm) thick, factory-installed throwaway filter, mounted in a 4-sided combination filter rack and return air duct collar. Filters can be easily removed from either side by interchanging the removable filter door to the right or left side and rotating the filter rack assembly 180 degrees. A 2" or 4" filter rack is available as a factory-installed selectable option to accept a Merv 8 or Merv 13 filter. All ductwork should conform to industry standards of good practice as described in ASHRAE Systems Guide. A field supplied discharge duct system will normally consist of: A flexible connector at the unit A 90 degree elbow without vanes A 10 ft length of insulated duct A trunk duct teeing into a branch circuit with discharge diffusers. Discharge Duct Collar Dimensions Figure 18: GSV discharge duct collar locations General 1. Verify the compatibility between the voltage and phase of the available power and that shown on the unit serial plate. Line and low voltage wiring must comply with local codes or the National Electrical Code, whichever applies. 2. Apply correct line voltage to the unit. A 7 8" (22mm) hole and/or a 1-1 8" (29 mm) knockout is supplied on the side of the unit. A disconnect switch near the unit is required by code. Power to the unit must be sized correctly and have dual element (Class RK5) fuses or an HACR circuit breaker for branch circuit overcurrent protection. See the nameplate for correct ratings. 3. Three phase 60 cycle units, 460/60-3, require a neutral wire for power to the fan circuit. 4. Connect the thermostat/subbase wiring with the power off to the unit. 5. Field supplied relays installed on the input terminals W1, W2, Y1, Y2 or G may introduce electrical noise. Never install relay coils in series with the inputs. 230 Volt Operation All volt single-phase and three-phase units are factory wired for 208 volt operation. For 230 phase operation, the line voltage tap on the 24 volt transformer must be changed. Disconnect and cap the red lead wire and interchange it with the orange lead wire on the primary of the 24 volt transformer (sizes ). Table 10: GSV discharge duct collar dimensions GSV Vertical Unit Discharge Duct Collar Connection in inches (mm) M N O P Q 007, 009, (270) 6.64 (169) 4.89 (124) 9.37 (238) (271) 015, (146) 8.16 (207) (265) 9.33 (237) (265) 024, (146) 8.37 (213) (264) 9.32 (237) (268) (164) 9.63 (245) (349) (337) 9.63 (245) 042, (164) 9.63 (245) (349) (337) 9.63 (245) 060, (164) 9.63 (245) (349) (337) 9.63 (245) Note: All duct dimensions are referenced from the outside edge of the flange. P N N P O Q Front O M Top View - Left Return Top View - Right Return IM 1139 / Page 15 of 52

16 Installation GSV Vertical Unit Figure 19: Typical installation using ducted return Duct piece from return air duct collar to boot Discharge Duct Flexible (Boot) Connector Flexible (Boot) Connector Isolation Pad Figure 20: Typical ducting for vertical unit 90 elbow Acoustically Insulated Duct (approximately 10') Flexible (Boot) Connector Trunk Duct Room Air Supply Diffuser Trunk Duct Tee Branch Duct Branch Duct Room Air Supply Diffuser Room Air Supply Diffuser Notes: 1. Transformation to supply duct have maximum slope of 1" in 7". 2. Square elbows with double thickness vanes may be substituted. 3. Do not install ducts so that the air flow is counter to fan rotation. If necessary, turn fan section. 4. Transformations and units must be adequately supported so no weight is on the flexible fan connection. Page 16 of 52 / IM 1139

17 Installation GSV Vertical Unit Piping & Electrical Connections Locations Figure 21: GSV piping & electrical connections locations 1.5" (38) Return Air Filter Rack Assembly & Duct Collar Connections Figure 23: GSV return air duct collar locations 2" Filter Rack 2" (51) Optional 4" Filter Rack 4" (102) X W W X FM AP 1.83" (47) 1.5" (38) Line Voltage Opening (Note 4) C AP Y V V Y L K J D E F G H Z Z Front View Low Voltage Opening (Note 3) Legend: C AP = Control Access Panel FM AP = Fan Motor Access Panel Figure 22: Unit with optional disconnect switch Line voltage hole in disconnect switch Disconnect switch Table 12: GSV return air duct collar dimensions Unit Size V W X Y Z 007, 009, , , , , (406) (419) 26.48" (673) 24.57" (624) 28.57" (726) 32.57" (827) (492) (565) 20.78" (528) 27.38" (696) 27.38" (696) 27.38" (696) (555) (611) 22.62" (575) 29.22" (742) 29.22" (742) 29.22" (742) (448) (461) (715) (667) (768) (870) (414) (476) (485) (597) (597) (597) Table 11: GSV piping & electrical connections dimensions GSV Vertical Unit Piping Connections in inches (mm) Electrical Connections in inches (mm) D E F G H J K L Supply Desuperheater Water Supply Desuperheater Water Return Return Condensate Drain 3/4" FPT Low Voltage 4 Between Line Voltage 5 007, 009, (67) N/A N/A 5.62 (143) (334) 2.08 (53) 7.06 (179) 9.14 (232) 015, (74) N/A N/A 5.90 (150) (408) 2.08 (53) 7.06 (179) 9.14 (232) 024, (66) 6.68 (170) 9.68 (246) (340) (442) 3.07 (78) 8.00 (203) (281) (83) 7.07 (180) (256) (357) (454) 3.82 (97) 8.25 (210) (307) 042, (78) 7.07 (180) (256) (353) (454) 3.82 (97) 8.25 (210) (307) 060, (78) 7.07 (180) (256) (353) (454) 3.82 (97) 8.25 (210) (307) Notes: 1 Supply and return piping connections = 1/2" (13 mm) FPT. 2 Supply and return piping connections = 3/4" (19 mm) FPT. 3 Supply and return piping connections - 1" (25.4 mm) FPT. 4 Low voltage opening = 7/8" (22 mm) diameter. 5 Line voltage opening = 1-1/8" (29 mm) diameter. IM 1139 / Page 17 of 52

18 System Applications Water Loop Application Commercial systems typically include a number of units connected to a common piping system. Any unit plumbing maintenance work can introduce air into the piping system; therefore air elimination equipment is a major portion of the mechanical room plumbing. In piping systems expected to utilize water temperatures below 50 F [10 C], 1/2 [13mm] closed cell insulation is required on all piping surfaces to eliminate condensation (extended range units required). Metal to plastic threaded joints should never be used due to their tendency to leak over time. All SmartSource units include flush mounted FPT water connections integral to the unit corner post, which do not require a backup wrench. Teflon tape thread sealant is recommended to minimize internal fouling of the heat exchanger. Do not over tighten connections and route piping so as not to interfere with service or maintenance access. Hose kits are available from Daikin McQuay in different configurations as shown in Figure 26 for connection between the unit and the piping system. Depending upon selection, hose kits may include shut off valves, P/T plugs for performance measurement, high pressure stainless steel braided hose, Y type strainer with blow down valve, and/or J type swivel connection. Balancing valves and an external low pressure drop solenoid valve for use in variable speed pumping systems may also be included in the hose kit. The piping system should be flushed to remove dirt, piping chips, and other foreign material prior to operation (see "Cleaning & Flushing System" on page 26. The flow rate is usually set between 2.25 and 3.5 gpm per ton [2.9 and 4.5 l/m per kw] of cooling capacity. Daikin McQuay recommends 3 gpm per ton [3.9 l/m per kw] for most applications of water loop heat pumps. To ensure proper maintenance and servicing, P/T ports are imperative for temperature and flow verification, as well as performance checks. Water loop heat pump (cooling tower/boiler) systems typically utilize a common loop, maintained between F [16-32 C]. The use of a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary. Figure 24: Typical water loop application (horizontal unit with optional unit mounted loop pumps Discharge Air Return Air 3/8" Threaded Rod (By Others) Discharge Duct Power Disconnect Unit Hanger Brackets Line Voltage Unit Power Low Voltage Thermostat Wiring Shutoff Ball Valves with P/T Ports & Flexible Hoses Unit Mounted Loop Pumps Building Loop Piping Page 18 of 52 / IM 1139

19 System Applications Ground-Loop Application CAUTION The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations. Piping Installation The typical closed loop ground source system is shown in Figure 26. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of the loop. Figure 25: Polyethylene fused piping CAUTION Ground loop applications require extended range equipment and optional refrigerant/water circuit insulation. Pre-Installation Prior to installation, locate and mark all existing underground utilities, piping, etc. Install loops for new construction before sidewalks, patios, driveways, and other construction has begun. During construction, accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation. Galvanized or steel fittings should not be used at any time due to their tendency to corrode. All plastic to metal threaded fittings should be avoided due to their potential to leak in earth coupled applications. A flanged fitting should be substituted. P/T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger. Figure 26: Typical ground loop application (loop pump by others shown) Line Voltage Wiring Low Voltage Thermostat Wiring Loop Pump Flow Controller Power Disconnect Supply & Return Ground Loop Piping Vibration Isolation Pad Shutoff Ball Valves with P/T Ports & Flexible Hoses IM 1139 / Page 19 of 52

20 System Applications Earth loop temperatures can range between 25 and 110 F [-4 to 43 C]. Flow rates between 2.25 and 3 gpm [2.41 to 3.23 l/m per kw] of cooling capacity is recommended in these applications. Test individual horizontal loop circuits before backfilling. Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kpa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled. Flushing the Earth Loop Upon completion of system installation and testing, flush the system to remove all foreign objects and purge to remove all air. All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes. Calculate the total volume of fluid in the piping system. Then use the percentage by volume shown in Table 13 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity. Figure 27: Flushing the loop Antifreeze In areas where minimum entering loop temperatures drop below 40 F [5 C] or where piping will be routed through areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales office should be consulted to determine the antifreeze best suited to your area. Freeze protection should be maintained to 15 F [9 C] below the lowest expected entering loop temperature. For example, if 30 F [-1 C] is the minimum expected entering loop temperature, the leaving loop temperature would be 22 to 25 F [-6 to -4 C] and freeze protection should be at 15 F [-10 C]. Calculation is as follows: 30 F - 15 F = 15 F [-1 C - 9 C = -10 C]. Table 13: Antifreeze percentage by volume Minimum Temperature for Low Temperature Protection Type 10 F [-12.2 C] 15 F [-9.4 C] 20 F [-6.7 C] 25 F [-3.9 C] Methanol 25% 21% 16% 10% l00% USP food grade Propylene Glycol 38% 25% 22% 15% Ethanol 1 29% 25% 20% 14% Note: 1 Must not be denatured with any petroleum product. Table 14: Antifreeze correction factors Antifreeze % by weight 15% 25% 35% 45% Ethanol Cooling Capacity Heating Capacity Pressure Drop 1.04 Ethylene Glycol Cooling Capacity Heating Capacity Pressure Drop Methanol Cooling Capacity Heating Capacity Pressure Drop 1.04 Propylene Glycol Cooling Capacity Heating Capacity Pressure Drop Page 20 of 52 / IM 1139

21 System Applications Ground-Water Application Open Loop - Ground Water Systems - Typical open loop piping is shown in Figure 28. Shut off valves should be included for ease of servicing. Boiler drains or other valves should be tee d into the lines to allow acid flushing of the heat exchanger. Shut off valves should be positioned to allow flow through the coax via the boiler drains without allowing flow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended. Water quantity should be plentiful and of good quality. See "Water impurities, result & recommended water system application" on page 23 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 16 for recommendations. Copper is recommended for open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupronickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualified technician, as acid and special pumping equipment is required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional acid flushing. In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required. Figure 28: Typical open loop application Optional (Field-Installed) Water Control Valve Flow Regulator Power Disconnect Pressure Tank Water Quality Standards - "Table 16: Water impurities, result & recommended water system application" on page 23 should be consulted for water quality requirements. Scaling potential should be assessed using the ph/calcium hardness method. If the ph <7.5 and the calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150 F [66 C] for direct use (well water/open loop) and DHW (desuperheater); 90 F [32 F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 16. Expansion Tank and Pump - Use a closed, bladder type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its draw-down capacity rating to prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain field, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area. Water Control Valve - Note the placement of the water control valve in Figure 28. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the return line to prevent mineral precipitation during the offcycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a miniexpansion tank can be mounted on the piping to help absorb the excess hammer shock. If a field provided motorized valve and actuator is utilized, ensure that the total VA draw of the valve can be supplied by the unit transformer. For instance, a slow closing valve can draw up to 35VA. Units are furnished with a factory-installed 50 VA transformer. An optional 75VA transformer is also available. A typical pilot operated solenoid valve draws approximately 15VA (see Figure 39). P/T Plugs Boiler Drains Optional Filter Shutoff Valve Supply Return IM 1139 / Page 21 of 52

22 System Applications Flow Regulation - Flow regulation can be accomplished by two methods. One method involves simply adjusting the ball valve or water control valve on the discharge line. Measure the pressure drop through the unit heat exchanger, and determine flow rate from Table 15. Since the pressure is constantly varying, two pressure gauges may be needed. Adjust the valve until the desired flow of 1.5 to 4 gpm, per ton [5.7 to 15.1 l/m, per kw] is achieved. A second method of flow control regulation requires a flow control device mounted on the outlet of the water control valve. The device is typically a brass fitting with an orifice of rubber or plastic material that is designed to allow a specified flow rate. On occasion, flow control devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line. Slightly closing the valve will spread the pressure drop over both devices, lessening the velocity noise. Table 15: Water pressure drop Pressure Drop, psi (kpa) Unit Size GPM 50ºF 70ºF 90ºF Page 22 of 52 / IM 1139

23 System Applications Water System Quality The cleaning, flushing and chemical treatment of a water source heat pump system is fundamental to efficient operation and the life expectancy of the system. Potential system problems produced by the use of water fall into three general categories: 1. Scale formation Mineral deposits which result from the crystallization and precipitation of dissolved salts in the water. The deposits form an insulating barrier, reducing the heat transfer rate and impeding the circulation of fluids due to increased pressure drop. 2. Corrosion Decomposition of the metal caused by absorption of gases from the air. Corrosion may occur in any metal component of the system. 3. Organic growths Slime and algae which form under certain environmental conditions, and can reduce the heat transfer rate by forming an insulating coating or can promote corrosion by pitting. The system water should be evaluated for degrees of impurity, with testing available from independent testing labs, health departments or state agencies. Table 16 is a list of water characteristics, the potential impurities and their results and the recommended treatment. Avoiding Potential Problems As shown in Table 16, all water contains some degree of impurities which may affect the performance of a heat pump system. The use of a cupro-nickel coil can help avoid potential problems. Water flow rates should: A. be high enough that the temperature rise through the heat exchanger does not exceed 10 F when operating in the cooling mode. B. not exceed 4 GPM per nominal ton. Flow rates that have velocities of 10 feet per second or more may cause pipe erosion and heat exchanger failure. Table 16: Water impurities, result & recommended water system application Impurity Copper Coils Curpro-nickel Coils Result Open Recirculating Application Closed Recirculating Calcium & Magnesium Salts (hardness) Less than 350 ppm 350 ppm Sea Water Scaling 1. Bleed-off 2. Surface active agents such as polyphosphates. 3. Addition of acid. 4. ph adjustment. Other considerations: Adequate fouling factor Surface temperature Water temperature Clean system No treatment required Iron oxide Low levels only Moderate levels ph Hydrogen Sulfide Less than 10 ppm ppm CO2 Less than 50 ppm ppm Chloride Less than 300 ppm ppm Total Dissolved Less than 1000 ppm ppm Solids Corrosion 1. Corrosion inhibitors in high concentrations (200 to 500 ppm). 2. Corrosion inhibitors in low concentrations (20 to 80 ppm). 3. ph control. 4. Proper materials of construction. Corrosion inhibitors in high concentrations. Proper materials of construction. Slime & Algae Slime and algae can form under certain environmental conditions Reduced heat transfer due to forming of insulating coating, or pitting due to corrosion Chlorinated phenols. Other biocides. Chlorine by hypochlorites or by liquid chlorine No treatment required Notes: 1. The tremendous variety in water quality around the country makes the recommendation of a single best method of treatment impossible. Consult a local water treatment specialist for specific treatment recommendations. 2. Cupro-nickel is recommended if iron bacteria is high, suspended solids or dissolved oxygen levels are high. 3. If the concentration of these corrosives exceeds the maximum tabulated in the cupro-nickel column, then the potential for serious corrosion problems exists. IM 1139 / Page 23 of 52

24 System Applications Supply & Return Piping All units should be connected to supply and return piping in a two-pipe reverse return configuration. A reverse return system is inherently self-balancing and requires only trim balancing where multiple quantities of units with different flow and pressure drop characteristics exist in the same loop. To insure proper water flow, measure the temperature differential between the supply and return connections. The temperature differential should be 10 F to 14 F (5 C to 8 C) for units in cooling mode. A direct return system may also work acceptably, but proper water flow balancing is more difficult to achieve and maintain. The piping can be steel, copper or PVC. Notes: Polyolester Oil, commonly know as POE oil is a synthetic oil used in many refrigeration systems. POE oil, if ever in contact with PVC/CPVC will coat the inside wall of PVC/CPVC pipe causing environmental stress fractures. Although there is no PVC/CPVC piping in this product, please keep this in mind when selecting piping materials for your application, as system failure and property damage could result. Supply and return runouts usually join the unit via short lengths of high pressure flexible hose which are sound attenuators for both unit operating noise and hydraulic pumping noise. One end of the hose should have a swivel fitting to facilitate removal for service. Hard piping can also be brought directly to the unit. Note: This option is not recommended since no vibration or noise attenuation can be accomplished. The hard piping must have unions to facilitate unit removal. See Figure 30 for a typical reverse return piping system. Some flexible hose threaded fittings are supplied with sealant compound. If not, apply Teflon tape to assure a tight seal. Figure 29: Example of a reverse return piping system Page 24 of 52 / IM 1139

25 Piping Figure 30: Typical horizontal unit piping Electrical Access Panel Hanger Kits (4) Flex Hoses Return Riser Note: Improper trapping can lead to several problems. If the trap is too tall, negative pressure will prevent drainage, causing condensate backup. If the trap is too short the seal will be destroyed or nonexistent, producing the same effect as a non-trapped system. Figure 32: Horizontal unit vinyl condensate hose & trap detail Condensate Riser Supply Riser Ball Valves Supply Air Note: Do not over-torque fittings. The maximum torque without damage to fittings is 30 foot pounds. If a torque wrench is not available, use as a rule of thumb, finger tight plus one quarter turn. 5. Supply and return shutoff valves are required at each conditioner. The return valve is used for balancing and should have a memory stop so that it can always be closed off but can only be reopened to the proper position for the flow required. 6. No unit should be connected to the supply and return piping until the water system has been cleaned and flushed completely, see "Cleaning & Flushing System" on page 26. After the cleaning and flushing has taken place, the initial connection should have all valves wide open in preparation for water system flushing. Condensate Drain Connection Vertical units are factory provided with a condensate drain trap located inside the cabinet. Condensate removal piping must be pitched away from the unit not less than 1/4" per foot. A vent is required after the trap so that the condensate will drain away from the unit. The vent can also act as a clean out if the trap becomes clogged. To avoid having waste gases entering the building, the condensate drain should not be directly piped to a drain/waste/vent stack. See local codes for the correct application of condensate piping to drains Figure 31: Unit condensate drain pipe trap detail C A B 7/8" I.D. Clear Plastic Table 17: Condensate drain static pressures Static Pressure A B C Standard 1-1/4" 5/8" 2-3/4" High 1-1/2" 3/4" 3-1/8" 1. Condensate piping can be steel, copper or PVC. Each unit includes a condensate connection. 2. The unit has a 3/4-inch female pipe fitting on each water source heat pump to accommodate the condensate drain connection. Factory supplied condensate hose assemblies have a pipe thread fitting to facilitate connection of a flexible vinyl or steel braided hose. A complete copper or PVC condensate system can be used. Union fittings in the copper or PVC lines should be applied to facilitate removal. 3. Do not locate any point in the drain system above the drain connection of any unit. 4. Automatic flow controlled devices must not be installed prior to system cleaning and flushing. 5. A high point of the piping system must be vented. 6. Check local code for the need for dielectric fittings. It may be necessary to manually fill the trap at system startup, or to run the unit for sufficient time to build a condensate seal. The condensate trap and condensate piping drainage should be free of any foreign debris. Debris can prevent proper drainage and unit operation and result in condensate buildup " (38mm) Optional Field- Installed Vent 1-1 2" (38mm) 1 4" Per Foot (21mm Per Meter) IM 1139 / Page 25 of 52

26 Piping Cleaning & Flushing System 1. Prior to first operation of any conditioner, the water circulating system must be cleaned and flushed of all construction dirt and debris. If the conditioners are equipped with water shutoff valves, either electric or pressure operated, the supply and return runouts must be connected together at each conditioner location. This will prevent the introduction of dirt into the unit. See Figure 33. Figure 33: Supply & return runouts connected together Flexible Hose Return Runout Supply Runout Mains Runouts Initially Connected Together 2. Fill the system at the city water makeup connection with all air vents open. After filling, close all air vents. The contractor should start main circulator with the pressure reducing valve open. Check vents in sequence to bleed off any trapped air, ensuring circulation through all components of the system. Power to the heat rejector unit should be off, and the supplementary heat control set at 80 F (27 C). While circulating water, the contractor should check and repair any leaks in the piping. Drains at the lowest point(s) in the system should be opened for initial flush and blowdown, making sure city water fill valves are set to make up water at the same rate. Check the pressure gauge at pump suction and manually adjust the makeup to hold the same positive steady pressure both before and after opening the drain valves. Flush should continue for at least two hours, or longer if required, to see clear, clean drain water. 3. Shut off supplemental heater and circulator pump and open all drains and vents to completely drain down the system. Short circuited supply and return runouts should now be connected to the conditioner supply and return connections. Do not use sealers at the swivel flare connections of hoses. 4. Trisodium phosphate was formerly recommended as a cleaning agent during flushing. However, many states and localities ban the introduction of phosphates into their sewage systems. The current recommendation is to simply flush longer with warm 80 F (27 C) water. 5. Refill the system with clean water. Test the water using litmus paper for acidity, and treat as required to leave the water slightly alkaline (ph 7.5 to 8.5). The specified percentage of antifreeze may also be added at this time. Use commercial grade antifreeze designed for HVAC systems only. Do not use automotive grade antifreeze. Once the system has been filled with clean water and antifreeze (if used), precautions should be taken to protect the system from dirty water conditions. Dirty water will result in system wide degradation of performance and solids may clog valves, strainers, flow regulators, etc. Additionally, the heat exchanger may become clogged which reduces compressor service life or 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 air vented and loop temperatures stabilized, each of the conditioners will be ready for check, test and start-up, air balancing, and water balancing. Page 26 of 52 / IM 1139

27 Controls Table 18: MicroTech III SmartSource unit controller terminals & descriptions H VAC Power Input H1 2 C 24 VAC common H2 1 SL1 Fan Main Required Output Switched L1 H2 2 Blank Terminal H2 3 N Fan Main Required Output Neutral H3 1 HP1-1 Comp High Pressure Switch (HP1) Input Terminal 1 H3 2 HP1-2 Comp High Pressure Switch (HP1) Input Terminal 2 H4 1 1 Discharge Air Temp Sensor Common H4 2 Discharge Air Temp Sensor Signal H4 3 Leaving Water Temp Sensor Common H4 4 Leaving Water Temp Sensor Signal H5 1 1 H5 2 H5 3 H5 4 H5 5 H5 6 Connections to I/O Expansion Board H5 7 H5 8 H5 9 H5 10 H5 11 H5 12 H6 1 1 Condensate Overflow Signal Input H6 2 Compressor Suction Temp Sensor (LT1) Common H6 3 Compressor Suction Temp Sensor (LT1) Signal H6 4 Compressor Low Pressure Switch (LP1) Source Voltage H6 5 Compressor Low Pressure Switch (LP1) Signal H6 6 Reversing Valve Common H6 7 Reversing Valve Output H7 1 1 No Connection H7 2 No Connection H7 3 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 H VAC Common H9 1 1 Room Temp Sensor & Tenant Override Signal H9 2 Room Temp Sensor & Tenant Override Common TB1 1 1 Room Sensor Status LED Output TB1 2 2 Room Sensor Fan Mode & Unit Mode Switches TB1 3 3 Room Sensor Setpoint Adjust Potentiometer TB1 4 4 Room Sensor Room Temp Sensor & Tenant Override TB1 5 5 Room Sensor DC Signal Common TB2 1 R 24 VAC TB2 2 A Thermostat Alarm Output TB2 3 W2 Thermostat Heat Stage #2 (W2) Input TB2 4 W1 Thermostat Heat Stage #1 (W1) Input TB2 5 Y2 Thermostat Cool Stage #2 (Y2) Input TB2 6 Y1 Thermostat Cool Stage #1 (Y1) Input TB2 7 G Thermostat Fan Input TB2 8 O Thermostat Heat Stage #3 (W3) Input TB2 9 C 24 VAC Common TB3 1 E Emergency Shutdown Input TB3 2 U Unoccupied 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 I/O expansion module connectors/terminals H1 1 1 H1 2 H1 3 H1 4 H1 5 H1 6 Connections to Main Board H1 7 H1 8 H1 9 H1 10 H1 11 H1 12 H2 1 1 Auxiliary Heat Stage #2 Output N/O H2 2 No Connection H VAC Common H3 1 1 Ext. 24 VAC In H3 2 Ext. 24 VAC Common In H3 3 HGR / Waterside Economizer Output N/O H3 4 Ext. 24 VAC Common H3 5 ECM Fan Motor Variable Speed Signal Output H3 6 ECM Fan Motor Variable Speed Signal Common H4 1 1 Entering Water Temp Sensor Signal H4 2 Entering Water Temp Sensor Common H5 1 1 No Connection H5 2 No Connection H5 3 Red LED Output H5 4 Green LED Output H5 5 Yellow LED Output H5 6 Red-Green-Yellow LED Common H6 1 HP2-1 Comp High Capacity High Press Sw (HP2) Input Terminal 1 H6 2 HP2-2 Comp High Capacity High Press Sw (HP2) Input Terminal 2 H7 1 Fan Speed Table Row Select Signal H7 2 Fan Speed Table Row Select Common H7 3 Thermostat Heat Stage #4 (W4) Input Signal H7 4 Auxiliary 24 VAC Out H8 1 1 Compressor High Capacity Output N/O H VAC Common H8 3 No Connection H8 4 Auxiliary Heat Stage #1 Output N/O H VAC Common TB1 1 1 Humidistat Signal Input TB1 2 2 Thermostat - Heat Stage #4 (W4) Input Signal IM 1139 / Page 27 of 52

28 Controls Figure 34: MicroTech SmartSource unit controller & I/O expansion module connectors descriptions Page 28 of 52 / IM 1139

29 Controls MicroTech III SmartSource Unit Controller The MicroTech III SmartSource unit controller is provided with two drive terminals, R (24VAC), and C (0VAC) that can be used to drive the thermostat inputs (G, Y1, Y2, W1, W2, W3, W4 and Humidistat) and control inputs (U, E and O). Any combination of or single board drive terminal (R, or C) may be used to operate the MicroTech III s unit controller or thermostat inputs. Some of the control inputs are used within the Water Source Heat Pump and not accessible to the end user without a field service tool (laptop with appropriate software). Typically the MicroTech III SmartSource unit controller's R (24VAC) terminal is used to drive the board s thermostat 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 SmartSource unit controller 's thermostat inputs. Any remaining board input(s) may be operated by additional thermostat outputs or remote relays (dry contacts only). All MicroTech III SmartSource 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 MicroTech III SmartSource unit controller inputs. No outside power sources may be used to operate Micro- Tech III. All units must be properly grounded per local code requirements. R 24VAC current R G = Thermostat fan input R Humidistat (HGR or Cooling at Dehumidification fan speed) R Y1 = Stage #1 Cooling R Y2 = Stage #2 Cooling R W1 = Stage # Heating R W2 = Stage #2 Heating R W3 Stage #3 Heating R W4 Stage #4 Heating The MicroTech III SmartSource unit controller has a lockout circuit to stop compressor operation if the high pressure or low pressure switch opens. If a compressor low suction temperature or freeze fault is detected, the unit will go into the cooling mode for 60 seconds to defrost any slush in the waterto-refrigerant heat exchanger. After 60 seconds the compres- sor is locked out. If the condensate sensor detects a filled drain pan, the compressor operation will be suspended only in the cooling mode. The unit is reset by opening and closing the disconnect switch on the main power supply to the unit in the event the unit compressor operation has been suspended due to low temperature (freezestat) switch, high pressure switch, or low pressure switch. The unit does not have to be reset on a condensate overflow detection. The MicroTech III SmartSource unit controller fault output sends a signal to an LED on a wall thermostat. Table 19 on page 30 shows for which functions the fault output is on (sending a signal to the LED). Unit Protections & LED Fault Status Annunciation Refrigerant Circuit High Pressure Protection A normally closed high (compressor discharge) pressure switch is used in SmartSource units to help protect the refrigerant circuit from excessively high pressure. The controller will monitor this switch. Note: Due to the method of sensing the HP switch, the true state cannot be determined unless the compressor output is active. Refrigerant Circuit Low Pressure Protection A normally closed low (compressor suction) refrigerant pressure switch is used in SmartSource units to help protect the refrigerant circuit from excessively low refrigerant pressure. The controller will monitor the switch, when the low-pressure switch contacts are open for more than the low-pressure time delay, default is 30 seconds, the controller will go into the low-pressure fault mode. Condensate Overflow Sensor (Cooling & Dehumidification Modes Only) The controller is designed to sense when condensate water levels in the drain pan become excessively high. When high condensate water levels are detected during cooling or dehumidification mode, the controller will go into condensate overflow warning mode. No condensate overflow warnings will occur when the unit is running in heating modes, thus allowing the unit to heat with high condensate water levels. The fan will operate normally during the condensate overflow fault mode. Heat Exchanger Low Temperature Protection The Suction Line Temperature sensor is located on the suction line of the compressor and is used to help protect the unit from excessively low water coil and air coil temperatures. The control module will monitor the SLT sensor and if the refrigerant temperature drops below the low temperature limit set point, the controller will go into the low temperature fault mode. The controller is programmed for different responses if a low temperature fault is detected during heating or cooling modes. IM 1139 / Page 29 of 52

30 Controls Low Refrigerant Temperature Protection in heating mode Low Refrigerant Temperature Protection in cooling mode Low Water Temperature Protection There are two versions of low water temperature protection, 1. Low Entering Water Temperature protection or; 2. Low Leaving Water Temperature protection. Emergency Shutdown The controller will be in remote shutdown when the emergency shutdown contact closes to ground. Remote shutdown is provided so that when properly connected to a water loop controller or remote switch, the emergency shutdown input can be used to shut down the water source heat pump. Low Voltage (Brownout) Protection The Baseboard controller module will monitor the 24 volt power input supplied to the board. If a low voltage condition is detected the control module will shut down the unit to protect electrical components from low line voltage conditions. Electrical Characteristics Line voltage feeds the primary side of the 24 volt transformer whose secondary output supplies power to the controls. When the line voltage drops, the transformer output voltage drops a corresponding amount. The Baseboard control module monitors the supply voltage from the transformer and after calibration will detect low line voltage conditions Low Voltage Calibration Process The Low Voltage Calibration process is first performed at the factory, and results in a Brownout Reference set point that will protect the unit under normal operating conditions in the field. Low Voltage Protection Control Sequence When the line voltage drops below 80% of the unit nameplate rated value, the controller senses the lower 24 volt supply voltage. Intelligent Alarm Reset This feature applies to faults that do not clear automatically. It is used to minimize nuisance trips of automatic lockouts caused by temporary conditions that might inhibit the unit from performing normal functions. When an Intelligent Reset alarm occurs, it is counted and the alarm is cleared when the condition returns to normal. If the alarm occurs two more (for a total of 3) times within a 24-hour period, the heat pump remains off (locked out) until the alarm is manually cleared. The control board is reset by a short interruption of unit power, or remotely reset by pressing the timed override button for more than 10 seconds, or through the service tool, or over the network. At the end of the 24 hour period, all counts for Intelligent Reset alarms are reset to zero. Remote Reset of Automatic Lockouts The Remote Reset feature provides the means to remotely reset automatic lockouts. There are (3) means to reset an automatic lockout condition: Using the thermostat create 2 demands for capacity within 30 seconds Press the Room Sensor or Thermostat Timed Override/ Reset Button for more than 10 seconds Turn the unit power off When the cause of the fault condition has been cleared, and the unit transitions from not requiring any capacity to needing any capacity twice within 30 seconds (accomplished by user manipulation of the Heat/Cool/Auto/Off switch on the thermostat), an alarm reset equivalent to a tenant override button reset is generated. The intelligent reset counter and the 24 hour timer are cleared when this type of alarm reset is generated. Note: This feature only applies to thermostat controlled systems. For room sensor controlled units, pressing the Override or Reset button for more than 10 seconds will apply a ground signal to the tenant override in(screw terminal connection at TB1 pin 4) will clear the lockout alarm once the cause of the fault condition has been cleared. A unit power cycle can also be used to clear an automatic lockout if the conditions causing the fault have been cleared. Table 19: MicroTech III SmartSource unit controller fault & status LED's Description Type Yellow Green Red IO Expansion Communication Fail Fault ON Flash Flash Invalid Configuration Fault Flash Flash OFF Low Voltage Brownout Fault OFF Flash OFF Emergency Shutdown Mode OFF Flash OFF Compressor High Pressure Fault OFF OFF Flash Compressor Low Pressure Fault OFF OFF ON Compressor Suction Temp Sensor Fail Fault Flash Flash ON Compressor Low Suction Temp Fault Flash OFF OFF Freeze Fault Detect Fault Flash OFF Flash Room Temp Sensor Fail (Room Sensor Control Only) Fault Flash Flash ON Leaving Water Temp Sensor Fail Fault Flash Flash ON Condensate Overflow Fault ON OFF OFF Serial EEPROM Corrupted Fault ON ON ON Waterside Economizer Low Temp Cutout (WSE Control & Call for Mode Flash ON Flash Cooling) Service Test Mode Enabled Mode Flash Flash Flash Unoccupied Mode Mode ON ON OFF Occupied, Bypass, Standby, or Tenant Override Modes Mode OFF ON OFF Note: Mode/faults are listed in order of priority. Page 30 of 52 / IM 1139

31 Controls Table 20: I/O expansion module fault & status LED's Description Type Yellow Green Red Baseboard Communication Fail Fault Flash OFF Flash Entering Water Temp Sensor Fail (Boilerless Electric Heat or Fault ON OFF Flash Waterside Economizer Only) Low Entering Water Temperature (No Display On Boilerless Fault OFF ON Flash Electric Heat) Fan is OFF Mode OFF ON OFF Fan Running at Low Speed (0 to 33%) Duty Cycle Mode OFF Flash OFF Fan Running at Medium Speed (34 to 66%) Duty Cycle Mode ON Flash OFF Fan Running at High Speed (67 to 100%) Duty Cycle Mode Flash Flash OFF MicroTech SmartSource Controller with LonWorks Communication Module For installation and operation information on LonWorks Communication Module and other ancillary control components, see: IM MicroTech III Water Source Heat Pump LonWorks Communication Module IM LonMaker Integration Plug-in Tool: For use with the MicroTech III SmartSource Unit Controller IM MicroTech III Wall Sensor for use with MicroTech III SmartSource Unit Controller Figure 35: LonWorks communication module Table 21: Fault recovery and reset Fault Description Auto Recovery Tenant Override Button Reset Network Reset I/O Expansion Communication Fail Yes No No Invalid Configuration No No No Low Voltage Brownout Yes No Yes All Sensor Failures No No Yes Compressor High Pressure No Yes Yes Compressor Low Pressure Yes 1 Yes Yes Compressor Low Suction Temp or Freeze Fault Detect (In Heating Yes 1 Yes Yes Mode) Compressor Low Suction Temp or Freeze Fault Detect (In Cooling or No Yes Yes Dehumidification Modes) Condensate Overflow Yes No Yes Low Entering Water Temp Yes No No Serial EEPROM Corrupted No No No Waterside Economizer Low Temp Cutout Yes No No Note: 1 Indicates auto recover is subject to intelligent alarm reset. Alarm auto recovers on first two occurrences, locked out on third within 24 hour period. See "Intelligent Alarm Reset" on page 30 for further details. MicroTech SmartSource Controller with BACnet Communication Module For installation and operation information on MicroTech III SmartSource unit controller and other ancillary components, see: IM MicroTech III BACnet Communication Module OM MicroTech III SmartSource Unit Controller for Water Source Heat Pumps Operation and Maintenance Manual IM MicroTech III Wall Sensor For use with MicroTech III SmartSource Unit Controller Figure 36: MicroTech III BACnet water source heat pump snap-in communication module IM 1139 / Page 31 of 52

32 Controls Figure 37: LonWorks or BACnet communication module placement on MicroTech III SmartSource unit controller Page 32 of 52 / IM 1139

33 Controls Rotary Fan Speed Selection Switch A 4-position rotary switch located in the control box allows CFM settings to be field adjustable. Fan speed control optimizes unit fan speed based on thermostat/room sensor inputs. The rotary switch allows for manually setting an optimal fan speed specific to the application requirements. Each position on the rotary switch represents settings 1-4, see Table 23 and Table 22. Figure 38: 4-position rotary fan speed switch Constant Torque Motor Table 22: Constant torque motor CFM values Unit Size Setting Function External Static Pressure (inches of water column) Setting Setting Stage 1 Setting Setting Setting Setting Stage 2 Setting Setting Setting Setting Fan Only Setting Setting Setting Setting Stage 1 Setting Setting Setting Setting Stage 2 Setting Setting Setting Setting Fan Only Setting Setting Setting Setting Stage 1 Setting Setting Setting Setting Stage 2 Setting Setting Setting Setting Fan Only Setting Setting Note: Gray tinted areas, below recommended operating range. IM 1139 / Page 33 of 52

34 Controls Constant CFM Type ECM Motor Fan Settings Table 23: Single stage units with constant CFM type ECM motor Unit Size Setting Maximum ESP (in. wg.) 1 Low CFM Heat 1 High CFM Heat 1 Low CFM Cool 1 High CFM Cool Fan Only Dehumidification Electric Heat Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Setting 4 (High) Setting 3 (Standard) Setting 2 (Medium) Setting 1 (Low) Note: 1 The unit is capable of high-low fan performance through the use of a 2-stage thermostat wired to specific terminals for High-Low CFM fan performance. Standard operation with a 1-stage thermostat is indicated as High CFM fan performance. Page 34 of 52 / IM 1139

35 Start-up Information for Initial 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. Check, Test & Start Procedure NOTICE Complete the "Water Source Heat Pump Equipment Check, Test and Start Form" on page Open all valves to full open position and turn on power to the conditioner. 2. Set thermostat for Fan Only operation by selecting Off at the system switch and On at the fan switch. If Auto fan operation is selected, the fan will cycle with the compressor. Check for proper air delivery. 3. Set thermostat to Cool. If the thermostat is an automatic changeover type, simply set the cooling temperature to the coolest position. On manual changeover types additionally select Cool at the system switch. Again, many conditioners have time delays which protect the compressor(s) against short cycling. After a few minutes of operation, check the discharge grilles for cool air delivery. Measure the temperature difference between entering and leaving water. It should be approximately 1½ times greater than the heating mode temperature difference. For example, if the cooling temperature difference is 15 F (8 C), the heating temperature difference should have been 10 F (5 C). Without automatic flow control valves, target a cooling temperature difference of 10 F to 14 F (5 C to 8 C). Adjust the combination shutoff/balancing valve in the return line to a water flow rate which will result in the 10 F to 14 F (5 C to 8 C) difference. 4. Set thermostat to Heat. If the thermostat is the automatic changeover type, set system switch to the Auto position and depress the heat setting to the warmest selection. Some conditioners have built-in time delays which prevent the compressor from immediately starting. With most control schemes, the fan will start immediately. After a few minutes of compressor operation, check for warm air delivery at discharge grille. If this is a cold building start-up, leave unit running until return air to the unit is at least 65 F (18 C). Measure the temperature difference between entering and leaving air and entering and leaving water. With entering water of 60 F to 80 F (16 C to 27 C), leaving water should be 6 F to 12 F (3.3 C to 6.6 C) cooler, and the air temperature rise through the machine should not exceed 35 F (19 C). If the air temperature exceeds 35 F (19 C), then the water flow rate is inadequate. 5. 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. 6. If the conditioner does not operate, check the following points: a. Is supply voltage to the machine compatible? b. Is thermostat type appropriate? c. Is thermostat wiring correct? 7. If the conditioner operates but stops after a brief period: 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; back flush unit if dirtclogged. 8. Check for vibrating refrigerant piping, fan wheels, etc. 9. Do not lubricate the fan motor during the first year of operation as it is pre lubricated at the factory. 10. Field supplied relays installed on the input terminals W1, W2, W3, W4, Humidistat, Y1, Y2 and G may introduce electrical noise. Never install relay coils in series with the inputs. IM 1139 / Page 35 of 52

36 Start-up Operating Limits Environment This equipment is designed for indoor installation only. Sheltered locations such as attics, garages, etc., generally will not provide sufficient protection against extremes in temperature and/or humidity, and equipment performance, reliability, and service life may be adversely affected. Table 24: Air limits in F ( C) Air Limits Standard Range Units Geothermal Range Units Cooling Heating Cooling Heating Minimum Ambient Air 50 F (10 C) 50 F (10 C) 40 F (4 C) 40 F (4 C) Maximum Ambient Air 100 F (38 C) 85 F (29 C) 100 F (38 C) 85 F (29 C) Minimum Entering Air 50 F (10 C) 50 F (10 C) 50 F (10 C) 40 F (4 C) Maximum Entering Air 100/83 F (38/28 C) 80 F (27 C) 100/83 F (38/28 C) 80 F (27 C) Table 25: Water limits Water Limits Standard Range Units Geothermal Range Units Cooling Heating Cooling Heating Minimum 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 (4 C) Maximum Entering Water 110 F (43 C) 90 F (32 C) 110 F (43 C) 90 F (32 C) Minimum GPM/Ton 1.5 Nominal GPM/Ton 3.0 Maximum GPM/Ton 4.0 Notes: 1. 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 conditions, but not more than two, with all other conditions being normal conditions. 2. 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. Factory-Installed Option Motorized Isolation Valve & Relay The motorized valve kit is available as a factory-installed and wired option or may be ordered as a field-installed accessory. Wired as shown in Figure 39, the motorized valve will open on a call for compressor operation. Valves for unit sizes 007 to 019 are 1/2" while unit sizes 024 to 070 are 3/4". The motorized isolation valve actuator (ISO) has both a 24V power connection and a 24V end switch connection. Figure 39: Motorized valve wiring Install the supplied wire harness into plug H8 on the main control board. Run wires between the ISO actuator and the supplied wire harness ends. Connect N.O & N.C. actuators as shown on the schematic Note: The actuator end switch is applicable for unit sizes 015 through 070 only. The end switch should be wired in series with the 24V compressor signal wire. Connect the end switch wires as shown in the schematic. The end switch will close when the valve is fully open. Note: For detailed installation instructions for the motorized valve, refer to IM Back to page 21 Page 36 of 52 / IM 1139

37 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (HGRH) V, 1-Phase IM 1139 / Page 37 of 52

38 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (HGRH) V, 1-Phase, Service & Disconnect Legend: Note: Devices in legend may or may not be on unit. ADR Aquastat, Discharge Refrigerant AHL Aquastat, High Limit AN1,2 LED Annunicator, circuit 1, 2 CO1-04 Fan Motor 1-4 Capacitor C11-12 Compressor 1,2 Capacitor CP1,2 Compressor 1, 2 COS Condensate Overflow Protection Sensor DAT Discharge Air Temperature Sensor DCS Disconnect Switch DSH Desuperheater Pump DSS Desuperheater Shutoff Switch EB1 Expansion Control Board 1 EB2 Expansion Control Board 2 - fan speed ctrl EH1 Electric Heat EWT Entering Water Temperature Sensor FM1-4 Fan Motor 1-4 GND Ground HG1,2 Hot Gas Reheat Valve Acutator HHT Hot Water Heat Valve Actuator HP1,2 High Pressure Switch 1, 2 HUM Humidistat Sensor ISO Water Flow Isolation Valve Actuator LAT Leaving Air Temperature Sensor LP1,2 Low Pressure Switch 1, 2 LT1,2 Compressor Suction Line Temperature Sensor 1, 2 LWT Leaving Water Temperature Sensor M01-04 Fan Motor 4 Contactor M11-1 Compressor 1, 2 Contactor M70, 71 Secondary Heat Contactor MCB Main Control Board NCB Network Control Board OLP Overload Protector - Compressor Motor PL1,2 Loop Pump 1, 2 R15 Relay, Field Contacts, Alarm Output R20 Relay, Loop Pump RAT Return Air Temperature Sensor RV1,2 Reversing Valve 1, 2 TB1 Terminal Block, Line Voltage TB2 Terminal Block, 24V TB3 Terminal Block, EH1 Line Voltage TR1 Transformer - Control TR2 Transformer - Fan Motor TR3 Transformer - Loop Pump TSL Thermostat, Wireless TSW Thermostat, Wired (Unit-mounted) W0001-^ Wire WH001-^ Wire Harness WN1-^ Wire Nut WP001-^ Wire Plug WPCP1 Wire Plug Assy - Compressor Power WPT01 Wire Plug Assy - 2-stage Comp Ctrl WSE Waterside Economizer Actuator Page 38 of 52 / IM 1139

39 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (WSE & DSH) V, 1-Phase with 115V Loop Pumps and 20kW Electric Heat IM 1139 / Page 39 of 52

40 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (WSE & DSH) Service & Disconnect V, 1-Phase with 115V Loop Pumps and 20kW Electric Heat Page 40 of 52 / IM 1139

41 Typical Wiring Diagrams MicroTech III Unit Control with LonWorks Communication Module V, 3-Phase with 230V Loop Pumps and 5kW Electric Heat IM 1139 / Page 41 of 52

42 Typical Wiring Diagrams MicroTech III Unit Control with LonWorks Communication Module Service & Disconnect V, 3-Phase with 230V Loop Pumps and 5kW Electric Heat Page 42 of 52 / IM 1139

43 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (WSE) - 460V, 3-Phase with 230V Loop Pumps and 20kW Electric Heat IM 1139 / Page 43 of 52

44 Typical Wiring Diagrams MicroTech III Unit Control with BACnet Communication Module (WSE) Service & Disconnect - 460V, 3-Phase with 230V Loop Pumps and 20kW Electric Heat Page 44 of 52 / IM 1139

45 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. 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. Maintenance 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 Daikin 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 Note: All information above is based on ISO standard and tested at these conditions. IM 1139 / Page 45 of 52

46 Troubleshooting Table 26: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 Normal TXV Restricted High Low High High Low Low Low Typical Refrigeration Cycles Figure 40: Cooling mode (single circuit only shown) Return Air Thermal Expansion Valve Co-Axial Heat Exchanger Coil Air to Refrigerant Heat Exchanger Water In Water Out Sensing Bulb and Capillary Tube Compressor Blower Reversing Valve Conditioned Air (Cooling) Cooling Refrigeration Cycle When the wall thermostat is calling for COOLING, the reversing valve directs the flow of the refrigerant, a hot gas, leaving the compressor to the water-to-refrigerant heat exchanger. Here the heat is removed by the water and the hot gas condenses to become a liquid. The liquid then flows through a thermal expansion metering system to the air-to-refrigerant heat exchanger coil. The liquid then evaporates becoming a gas, at the same time absorbing heat and cooling the air passing over the surfaces of the coil. The refrigerant then flows as a low pressure gas through the reversing valve and back to the suction side of the compressor to complete the cycle. Page 46 of 52 / IM 1139