McQuay FDL Series Installation & Maintenance Data

Brand: McQuay

Model: FDL Series

Category: Split-system air conditioners

Type: Installation & Maintenance Data

This manual is also suitable for

Contents

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

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

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

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

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

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

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

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

Wiring diagrams ............................................................. 8–14

Unit operation .................................................................... 15

LED Status and Fault Output Status .................................. 16

Thermostat Connections, Mark IV/AC units ....................... 17

Options for Mark IV/AC units ....................................... 19–22

Troubleshooting ................................................................. 23

Maintenance ...................................................................... 24

Installation & Maintenance Data IM 407-16

Group: WSHP

Part Number: 106581203

Date: June 2006

Vertical Water Source Heat Pump

& Cooling Only Units

Models FDD, FDE, FDL, FDS, FME, FMS

Page 2 of 24 / IM 407

Installation

General

1. To prevent damage, this equipment should not be oper-

ated for supplementary heating and cooling during the

construction period.

2. Inspect the carton for any specific tagging numbers as

requested by the installing contractor. At this time the

voltage, phase and capacity should be checked against

the plans.

3. Check the unit size against the plans to be sure that the

unit will be installed in the correct location.

4. Before installation, check the available closet dimensions

versus the dimensions of the unit.

5. Pay attention to the location and routing of water piping,

and electrical wiring. The locations of these items are

clearly marked on submittal drawings.

6. The installing contractor will find it beneficial to confer

with piping, sheet metal, ceiling and electrical foremen

together before installing any conditioners.

7. Remove shipping block from under the fan wheel.

8. We recommend that the contractor cover the condition-

ers with plastic film to protect the machines during finish-

ing of the building. This is important if spraying fireproof-

ing material on bar joists, sandblasting, spray painting

and plastering operations have not been completed. If

plastic film is not available, the shipping carton may be

modified to cover the units during construction.

9. On extra-quiet construction units with spring mounted

compressors, remove the shipping block under the com-

pressor.

Transportation and Storage

Upon receipt of the equipment, check carton for visible

damage. Make a notation on the shipper’s delivery ticket

before signing. If there is any evidence of rough handling, the

cartons should be opened at once to check for concealed

damage. If any damage is found, notify the carrier within 48

hours to establish your claim and request their inspection

and a report. The Warranty Claims Department should then

be contacted.

Do not stand or transport the machines on end. For

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

In the event that elevator transfer makes upended posi-

tioning unavoidable, absolutely insure that the machine is in

the normal upright position for at least 24 hours before

operating.

Temporary storage at the jobsite must be indoors, com-

pletely shielded from rain, snow, etc. High or low tempera-

tures naturally associated with weather patterns will not

harm the conditioners. Excessively high temperatures of

140

F (60

C) may deteriorate certain plastic materials and

cause permanent damage. In addition, the solid-state circuit

boards may experience operational problems.

Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and

regulations, and are experienced with this type of equipment. Caution: Sharp edges are a potential injury hazard. Avoid contact

with them.

Model Nomenclature

W FDD 1 009 E Z

Product Category

W = WSHP

Product Identifier

See box below

Design Series

1 = A Design

2 = B Deisgn

3 = C Design

4 = D Design

5 = E Design

Nominal Capacity

007 = 7,000

009 = 9,000

012 = 12,000

015 = 15,000

019 = 19,000

etc. . .

Coil Options

(None)

Voltage

E= 208/230-60-1

F= 208/230-60-3

J= 265-60-1

K= 460-60-3

L= 575-60-3

M= 230-50-1

N= 380-50-3

McQuay Product Identifiers

FDD = Floor Mtd/DDC Controls/Ext. Range/Less Board FDS = Floor Mtd/DDC Controls/Std. Range

FDE = Floor Mtd/DDC Controls/Ext. Range FME = Floor Mtd/Mark IV/Ext. Range

FDL = Floor Mtd/DDC Controls/Std. Range/Less Board FMS = Floor Mtd/Mark IV/Std. Range

IM 407 / Page 3 of 24

Unit location

1. Locate the unit in an area that allows for easy removal of

the filter and access panels, and has enough space for

service personnel to perform maintenance or repair. Pro-

vide sufficient room to make water, electrical and duct

connections.

2. The contractor should make sure that access has been

provided including clearance for duct collars and fittings

at water and electrical connections.

3. Allow adequate room around the unit for a condensate

trap.

4. The unit can be installed “free standing” in an equipment

room; however, closet installations are more common for

small vertical type units. Generally, the unit is located in

the corner of a closet with the nonducted return air facing

to the door and the major access panels facing the

door as in Figure 1A. Alternatively, the unit can have a

ducted return air with the opening facing the door and the

major access panels facing 90

to the door as in Figure 1B.

Figure 1A. Typical closet installation with louver door return

Figure 1B. Typical closet installation with ducted return

Heat Pump

With Left-Hand

Return Air Arrangement

Return

Air

Elec. Entrance

Opt. Controls

Main Access Panel

Condensate

Water Supply

Water Return

Heat Pump

With Right-Hand

Return Air Arrangement

Return

Air

Opt. Controls

Elec. Entrance

Main Access Panel

Condensate

Water Supply

Water Return

Return Air Thru

Louvered Door

RisersReturn Air Thru

Louvered Door

Heat Pump

With Left-Hand

Return Air Arrangement

Heat Pump

With Right-Hand

Return Air Arrangement

Main Access Panel Main Access Panel

Elec. Entrance

Opt. Controls

Elec. Entrance

Opt. Controls

Water Return

Condensate

Risers

Condensate

Water Supply

Water Return

Water Supply

Return

Air

Duct &

Grille

Return

Air

Duct &

Grille

5. It is recommended that the unit be located on top of a

vibration absorbing material such as rubber or carpet to

reduce any vibration. See Figure 5.

6. If optional field installed controls are required (boilerless

system), space must be provided for the enclosure to

mount around the corner from the electrical entrances. Do

not locate the side of the unit too close to a wall. See

Figures 1A and 1B.

Minimum distance requirement from return air duct

collar to wall, for non-ducted units.

Model Distance

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

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

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

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

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

Filter access

Each unit is shipped with a filter bracket for side filter re-

moval.

NOTE: Minimum distance

requirement for non-ducted

units. (see chart above)

Page 4 of 24 / IM 407

Ductwork and attenuation

Discharge ductwork is normally used with these condition-

ers. Return air ductwork may also be required, but will require

field installation of a return air duct collar/2" (51mm) filter rack

kit.

All ductwork should conform to industry standards of

good practice as described in ASHRAE Systems Guide.

The discharge duct system will normally consist of a

flexible connector at the unit, a noninsulated transition piece

to the full duct size, a short run of duct, an elbow without

vanes, and a trunk duct teeing into a branch circuit with

discharge diffusers as shown in Figure 2. The transition piece

must not have an angle greater than 30

or severe loss of air

performance can result. Do not connect the full duct size to

the unit without using a transition piece down to the size of

the discharge collar on the unit. With metal duct material, the

sides only of the elbow and entire branch duct should be

internally lined with acoustic insulation for sound attenua-

tion. Glass fiber duct board material is more absorbing and

may permit omission of the flexible connector.

The ductwork should be laid out so that there is no line of

sight between the conditioner discharge and the distribution

diffusers.

Return air ducts can be brought in through a wall grille and

then to the unit. The return duct system will normally consist

of a flexible connector at the unit and a trunk duct to the

return air grille. With metal duct material, the return air duct

should be internally lined with acoustic insulation for sound

attenuation. Glass fiber duct board material is more absorb-

ing and may permit omission of the flexible connector.

Return air ductwork to the unit requires the optional return

air duct collar/2" (51mm) filter rack kit. See Figure 3. The kit

can be installed for face side or bottom filter removal. The

flexible connector can then be attached to the 1" (25mm)

duct collar.

Do not use sheet metal screws directly into the unit

cabinet for connection of supply or return air ductwork,

especially return air ductwork which can puncture the drain

pan or the air coil.

Figure 2.

Ventilation air

Outside air may be required for ventilation. The temperature

of the ventilation air must be controlled so that mixture of

outside air and return air entering the conditioner does not

exceed application limits. It is also general practice to close

off the ventilation air system during unoccupied periods

(night setback).

The ventilation air system is generally a separate building

subsystem with distribution ductwork. Simple introduction

of the outside air into each return air plenum chamber

reasonably close to the conditioner air inlet is not only

adequate, but recommended. Do not duct outside air directly

to the conditioner inlet. Provide sufficient distance for thor-

ough mixing of outside and return air. See “Operating limits”

on page 7.

Figure 3.

Sizes 007 thru 042 Sizes 048 & 060

Heat Pump

Duct

Transition

Discharge Collar

(on Heat Pump)

Square Elbow

(Both Sides

Internally Lined

With Acoustic

Insulation)

Trunk Duct

Branch Duct

(Internally

Lined)

2 ft. x 2 ft

Diffuser

Canvas

Collar

IM 407 / Page 5 of 24

Electrical Data

General

1. Be sure the available power is the same voltage and phase

as that shown on the unit serial plate. Line and low voltage

wiring must be done in accordance with local codes or the

National Electrical Code, whichever is applicable.

2. Apply correct line voltage to the unit. A

⁄8" (22mm) or 1

⁄8"

(29mm) hole is supplied on the side of the unit. A discon-

nect switch near the unit is required by code. Power to the

unit must be sized correctly and have time delay (dual

element) fuses or an HACR circuit breaker for branch

circuit overcurrent protection. See the nameplate for

correct ratings.

230 Volt operation and 50 cycle units

All 208-230 volt single and three-phase units are factory

wired for 208 volt operation. For 230 volt operation, the line

voltage tap on the 24 volt transformer must be changed.

Disconnect and cap the red lead wire and interchange it with

the orange lead wire on the primary of the 24 volt trans-

former. Three-phase 50 cycle units require a neutral wire for

230/50/1 power.

Fan speed change

All units have two-speed fan motors and are shipped for

high speed operation. On unit sizes 007, 009 and 012, the

change from high speed to low speed is done by removing

the black wire from the fan relay and connecting the red wire

to the fan relay (Figure 4A). On units sizes 015 through 060,

each fan motor is supplied with a 5-pin terminal block

mounted on the fan motor. To change from high speed to

low speed, move the wire from the black #3 location to the

red #4 location on unit sizes 015 through 042 or to the red

#5 location on units sizes 048 and 060. On 575 volt units,

add a jumper between black #3 and blue #4 for low speed

operation. See Figure 4B.

Figure 4A. Figure 4B.

1. All units are recommended to be connected to supply

and return piping in a two-pipe reverse return configura-

tion. A reverse return system is inherently self-balancing

and requires only trim balancing where multiple quanti-

ties of units with different flow and pressure drop char-

acteristics are connected to the same loop. A simple

way to check for proper water balance is to take a

differential temperature reading across the water con-

nections. To insure proper water flow, the differential

should be 10

F (5

C) to 14

F (8

C).

A direct return system may also be made to work ac-

ceptably, but proper water flow balancing is more diffi-

cult to achieve and maintain.

2. The piping can be steel, copper or PVC.

3. Supply and return runouts are usually connected to the

unit by short lengths of high pressure flexible hose which

are sound attenuators for both unit operating noise and

hydraulic pumping noise. One end of the hose should

have a swivel fitting to facilitate removal for service. Hard

piping can also be brought directly to the unit although

it is not recommended since no vibration or noise at-

tenuation can be accomplished. The hard piping must

have unions to facilitate unit removal. See Figure 5 for

typical piping setup.

4. Supply and return shutoff valves are required at each

conditioner. The return valve is used for balancing and

should have a “memory stop” so that it can always be

closed off but can only be reopened to the proper

Piping

position for the flow required.

5. No unit should be connected to the supply and return

piping until the water system has been cleaned and

flushed completely. After the cleaning and flushing has

taken place, the initial connection should have all valves

wide open in preparation for water system flushing.

6. Condensate piping can be steel, copper or PVC. Each

unit is supplied with a

⁄8" (22mm) ODM copper stub.

7. The condensate disposal piping must have a trap and

the piping must be pitched away from the unit not less

than

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

condensate trap is made of copper and soldered on the

unit. See Figure 6. A piece of vinyl hose from the trap to

the drain line is used for simple removal. A complete

copper or PVC condensate system can also be used.

Union fittings in the copper lines should be applied to

facilitate removal. Factory supplied condensate hose

assemblies have a

⁄8" (22mm) sweat to FPT fitting to

facilitate connection of a flexible vinyl, rubber or steel

braided hose.

8. No point in the drain system may be above the drain

connection of any unit.

9. Automatic flow controlled devices must not be installed

prior to system cleaning and flushing.

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

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

RED (LOW SPEED)

BLACK (HIGH SPEED)

BROWN (CAPACITOR)

COMMON (WHITE)

FAN

MOTOR

FAN

MOTOR

YELLOW 1

BROWN 2

BLACK 3

*RED 4

*RED 5

COMMON

CAPACITOR

HIGH SPEED

LOW SPEED

JUMPER

*On unit sizes 048 and 060, terminal 4 is color-

coded blue and terminal 5 is color-coded red.

Page 6 of 24 / IM 407

Figure 5. Figure 6.

Balancing

Valve With

Close-off

Flexible Hose

With Brass

Pipe Fitting

Supply

Return

Condensate

Isolator Pad

Electrical &

Compressor

Access

Blower

Motor

Access

Note: Condensate drain connection must be minimum of 1" (25mm)

below connection to heat pump.

⁄4'' Per Foot

(21mm Per Meter)

Optional Cleanout

⁄2"

(38mm)

⁄2"

(38mm)

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

to the conditioners.

2. Set thermostat for “Fan Only” operation by selecting

“Off” at the system switch and “On” at the fan switch. If

“Auto” fan operation were selected, the fan would cycle

with the compressor. Check for proper air delivery.

3. All units have two-speed motors. Reconnect for low

speed operation if necessary.

4. Set thermostat to “Cool.” If the thermostat is an auto-

matic changeover type, simply set the cooling tempera-

ture to the coolest position. On manual changeover

types additionally select “Cool” at the system switch.

Start-up

1. Prior to first operation of any conditioner, the water cir-

culating system must be cleaned and flushed of all con-

struction dirt and debris.

If the conditioners are equipped with water shutoff

valves, either electric or pressure operated, the supply

and return runouts must be connected together at each

conditioner location. This will prevent the introduction of

dirt into the unit. Additionally, pressure operated valves

only open when the compressor is operating.

Figure 7.

2. The system should be filled at the city water makeup con-

nection with all air vents open. After filling, vents should be

closed.

The contractor should start main circulator with pres-

sure reducing valve makeup open. Vents should be

checked in sequence to bleed off any trapped air to

assure circulation through all components of the system.

Power to the heat rejector unit should be off, and the

supplementary heat control set at 80

F (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 blow-down, making sure city water fill valves are set

to make up water at the same rate. Check the pressure

gauge at pump suction and manually adjust the makeup

to hold the same positive steady pressure both before and

after opening the drain valves. Flush should continue for

at least two hours, or longer if required, to see clear, clean

drain water.

3. Supplemental heater and circulator pump should be shut

off. All drains and vents should be opened to completely

drain down the system. Short circuited supply and return

runouts should now be connected to the conditioner

supply and return connections. Teflon tape is recom-

mended over pipe dope for pipe thread connections. Use

no sealers at the swivel flare connections of hoses.

4. Trisodium phosphate was formerly recommended as a

cleaning agent during flushing. However, many states

and localities ban the introduction of phosphates into

their sewage systems. The current recommendation is to

simply flush longer with warm 80

F (27

C) water.

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

for acidity, and treat as required to leave the water slightly

alkaline (pH 7.5 to 8.5). The specified percentage of

antifreeze may also be added at this time. Use commer-

cial grade antifreeze designed for HVAC systems only. Do

not use automotive grade antifreeze.

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

to 70

F (21

C) and the heat rejection setpoint to 85

(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 and for air and water balancing.

Cleaning and Flushing System

Note: Do not overtorque fittings. The maximum torque without damage to fittings is 30 foot pounds. If a torque wrench is not available, use as a rule of thumb,

finger-tight plus one quarter turn. Use two wrenches to tighten the union, one to hold the line and one for simultaneous tightening of the nut.

Supply Runout

Return Runout

Mains

Runouts Initially

Connected Together

Rubber Hose

Electrical Access Panel

IM 407 / Page 7 of 24

exceed 35

F (19

C). If the air temperature exceeds 35

(19

C), the airflow rate is probably inadequate.

If the water temperature difference is less than 6

(3.3

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

temperature difference exceeds 12

F (6.7

C), then the

water flow rate is inadequate.

6. Check the elevation and cleanliness of the condensate

line. If the air is too dry for sufficient dehumidification,

slowly pour enough water into the condensate pan to

ensure proper drainage.

7. If the conditioner does not operate, the following points

should be checked:

a. Is proper voltage being supplied to the machine?

b. Is the proper type of thermostat being used?

c. Is the wiring to the thermostat correct?

8. If the conditioner operates but stops after a brief period,

check for:

a. Is there proper airflow? Check for dirty filter, incorrect

fan rotation (3-phase fan motors only), or incorrect

ductwork.

b. Is there proper water flow rate within temperature

limits? Check water balancing; backflush unit if dirt

clogged.

9. Check the unit for vibrating refrigerant piping, fan wheels,

etc.

10. Do not lubricate the fan motor during the first year of

operation as it is prelubricated at the factory.

Again, many conditioners have time delays which

protect the compressor against short cycling. After a

few minutes of operation, check the discharge grilles for

cool air delivery. Measure the temperature difference

between entering and leaving water. It should be ap-

proximately 1

⁄2 times greater than the heating mode

temperature difference. For example, if the cooling tem-

perature difference is 15

F (8

C), the heating tempera-

ture difference should have been 12

F (5

C).

Without automatic flow control valves, a cooling

temperature difference of 10

F to 14

F (5

C to 8

C) is

about right. Adjust the combination shutoff/balancing

valve in the return line to a water flow rate which will

result in the 10

F to 14

F (5

C to 8

C) difference.

5. Set thermostat to “Heat.” If thermostat is the automatic

changeover type, set system switch to the “Auto” posi-

tion and depress the heat setting to the warmest selec-

tion. 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 enter-

ing 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 6.7

C) cooler, and

the air temperature rise through the machine should not

Operating Limits

Environment

This equipment is designed for indoor installation only.

Sheltered locations such as attics, garages, etc., generally

will not provide sufficient protection against extremes in

temperature and/or humidity, and equipment performance,

reliability, and service life may be adversely affected.

Power supply

A voltage variation of ±10% of nameplate utilization voltage

is acceptable. Three-phase system unbalance shall not ex-

ceed 2%.

Operating voltages

115/60/1............................... 104 volts min.; 127 volts max.

208-230/60/1 ....................... 197 volts min.; 253 volts max.

265/60/1............................... 238 volts min.; 292 volts max.

230/50/1............................... 197 volts min.; 253 volts max.

460/60/3............................... 414 volts min.; 506 volts max.

380/50/3............................... 342 volts min.; 418 volts max.

575/60/3............................... 515 volts min.; 632 volts max.

Note: Voltages listed are to show voltage range. However,

units operating with overvoltage and undervoltage for

extended periods of time will experience premature

component failure.

Additional information

1. Standard units — Units are designed to start-up in an

ambient of 40

F (5

C), with entering air at 40

F (5

C), with

entering water at 70

F (21

C), with both air and water at

the flow rates used in the ARI Standard 320-86 rating test,

for initial start-up in winter.

Note: This is not a normal or continuous operating con-

dition. It is assumed that such a start-up is for the purpose

of bringing the building space up to occupancy

temperature.

2. Extended range units — Extended range heat pump

conditioners are designed to start-up in an ambient of

F (5

C), with entering air at 40

F (5

C), with entering

water at 40

F (5

C), with both air and water at the flow

rates used in the ARI Standard 320-86 rating test, for initial

start-up in winter.

Note: This is not a normal or continuous operating

condition. It is assumed that such a start-up is for the

purpose of bringing the building space up to occupancy

temperature.

Water enthalpy

Cooling Heating Cooling Heating

Min. Ent. Water

➀ ➁

F/13

C55

F/13

C40

F/5

C40

F/5

Normal Ent. Water 85

F/29

C70

F/21

C85

F/29

C70

F/21

Max. Ent. Air,

➀ ➁

110

F/43

C90

F/32

C 110

F/43

C90

F/32

Air and water limits

STANDARD EXTENDED

UNITS RANGE UNITS

Cooling Heating Cooling Heating

Min. Amb. Air 50

F/10

C50

F/10

C40

F/5

C40

F/5

Normal Amb. Air 80

F/27

C70

F/21

C80

F/27

C70

F/21

Max. Amb. Air 100

F/38

C85

F/29

C 100

F/38

C85

F/29

Min. Ent. Air ➀ ➁ 50

F/10

C50

F/10

C50

F/10

C40

F/5

Normal Ent. Air, 80/67

F70

F 80/67

F70

db/wb 27/19

C21

C 27/19

C21

Max. Ent. Air, 100/83

F80

F 100/83

F80

db/wb ➀ ➁ 38/28

C27

C 38/28

C27

➀ At ARI flow rate

➁ Maximum and minimum values may not be combined. If one value is at

maximum or minimum, the other two conditions may not exceed the

normal condition for standard units. Extended range units may combine

any two maximum or minimum conditions, but not more than two, with all

other conditions being normal conditions.

Page 8 of 24 / IM 407

60 Cycle Wiring Diagrams — Mark IV/AC Units

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

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is

used, transformer must be rewired by disconnecting the power

from the red transformer primary wire and connecting the power

lead to the orange transformer primary wire. Place an insulation

cap on the red transformer primary wire.

3. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is

used, transformer must be rewired by disconnecting the power

from the red transformer primary wire and connecting the power

lead to the orange transformer primary wire. Place an insulation

cap on the red transformer primary wire.

3. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

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

IM 407 / Page 9 of 24

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is

used, transformer must be rewired by disconnecting the power

from the red transformer primary wire and connecting the power

lead to the orange transformer primary wire. Place an insulation

cap on the red transformer primary wire.

3. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 10. Unit sizes 019 through 048 (208-230, 265 volts, single-phase) 060686606 Rev. C

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is

used, transformer must be rewired by disconnecting the power

from the red transformer primary wire and connecting the power

lead to the orange transformer primary wire. Place an insulation

cap on the red transformer primary wire.

3. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 11. Unit sizes 060 (208-230 volts, single-phase) 063393303 Rev. C

Page 10 of 24 / IM 407

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Unit is factory wired for 230V operation. If 230V power supply is

used, transformer must be rewired by disconnecting the power

from the red transformer primary wire and connecting the power

lead to the orange transformer primary wire. Place an insulation

cap on the red transformer primary wire.

3. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

4. All temperature and pressure switches are normally closed.

5. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 12. Unit sizes 024 through 060 (208-230 volts, three-phase) 060686704 Rev. B

Figure 13. Unit sizes 024 through 060 (460 and 575 volts, three-phase) 060686804 Rev. B

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

IM 407 / Page 11 of 24

50 Cycle Wiring Diagrams — Mark IV/AC Units

Figure 14. Unit sizes 007 through 012 (230 volts, single-phase) 061415316 Rev. A

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 15. Unit sizes 015 through 019 (230 volts, single-phase) 061415318 Rev. A

Page 12 of 24 / IM 407

Figure 16. Unit sizes 024 (230 volts, single-phase) 061415320 Rev. A

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 17. Unit sizes 048 and 060 (230 volts, single-phase) 063393303 Rev. C

IM 407 / Page 13 of 24

Figure 18. Unit sizes 024 through 042 (380 volts, three-phase) 061415321 Rev. A

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Notes:

1. Mark IV/AC controller board contains a static sensitive micropro-

cessor. Proper grounding of field service personnel is required or

damage to controller may result.

2. Terminal block on Mark IV/AC board provides 24 VAC at termi-

nals R and C. All other terminals are 24 VDC output.

3. All temperature and pressure switches are normally closed.

4. Field supplied relays attached to the 24 volt terminals R, W, Y or

G may introduce electrical noise. Never install relays in series

with the inputs.

Figure 19. Unit sizes 048 and 060 (380 volts, three-phase) 061415322 Rev. A

Page 14 of 24 / IM 407

Figure 20. Typical MicroTech 2000 WSHP unit controller single circuit wiring diagram

Notes:

1. Unit is factory wired for 208V operation. If 230V power supply is

used, transformer must be wired by disconnecting the power

lead from the red transformer primary wire. Place an insulation

cap on the red transformer primary wire.

2. All temperature and pressure switches are normally closed.

3. Wires 71 and 72 used only on units with no factory installed

options.

IM 407 / Page 15 of 24

Unit Operation

Figure 28.

INDICATION

LEDS FAULT

YELLOW GREEN RED OUTPUT

Normal mode Off On Off Off

High pressure fault Off Off Flash On

* Low temperature fault Flash Off Off On

Condensate overflow On Dim Off On

Brownout Off Flash Off On

Load shed Off Off On Off

Unoccupied mode On On Off Off

Unit shutdown Off Flash Off On

General

Each unit has a printed circuit board control system. The low

voltage output from the low voltage terminal strip on the

control board is always 24 volts DC (direct current). Termi-

nals R and C on the low voltage terminal strip supply 24 volts

AC power. The unit has been designed for operation with a

24 volt mercury bulb type wall thermostat or a microelec-

tronic wall thermostat selected by the manufacturer. Do not

operate the unit with any other type of wall thermostat.

Two types of units are available: electromechanical con-

trol units or Mark IV/AC control units. Both have 24 volt DC

circuits on the output of the low voltage terminal strip. Each

requires its own unique automatic changeover thermostat.

Mark IV/AC control units

The Mark IV/AC circuit board is an optional control system

with built-in features such as random start, compressor time

delay, night setback, load shed, shutdown, condensate

overflow protection, defrost cycle, brownout, and LED/fault

outputs. Figure 28 shows the LED and fault output se-

quences.

The 24 volt low voltage terminal strip is set up so R-G

energizes the fan, R-Y1 energizes the compressor for cool-

ing operation, R-W1 energizes the compressor and reversing

valve for heating operation. The reversing valve is set up to

be energized in the heating mode. The circuit board has a fan

interlock circuit to energize the fan whenever the compressor

is on if the thermostat logic fails to do so.

The Mark IV/AC control board has a lockout circuit to stop

compressor operation if any one of its safety switches opens

(high pressure switch and low pressure switch on unit sizes

048 and 060). If the low temperature switch opens, the unit

will go into the cooling mode for 60 seconds to defrost any

slush in the water-to-refrigerant heat exchanger. After 60

seconds the compressor is locked out. If the condensate

sensor detects a filled drain pan, the compressor operation

will be suspended only in the cooling mode. The unit is reset

by opening and closing the disconnect switch on the main

power supply to the unit in the event the unit compressor

operation has been suspended due to low temperature

(freezestat) switch, high pressure switch, or low pressure

switch on unit sizes 048 and 060. The unit does not have to

be reset on a condensate overflow detection.

The Mark IV/AC control board has a fault output signal to

an LED on a wall thermostat. Figure 28 shows for which

functions the fault output is “on” (sending a signal to the

LED).

The Mark IV/AC control board has built-in night setback

operation. A “grounded” signal to the “U” terminal on the low

voltage terminal strip puts the unit into the unoccupied mode

for night setback operation. The fan shuts off and the unit is

put under control from the night setback terminal on the

thermostat, W2; day heating and cooling operation is locked

out. R-W2 energizes the compressor and reversing valve for

heating operation. Night setback operation can be overrid-

den for two hours by toggling the fan switch (intermittently

closing the R to O terminals) on the Deluxe Auto Changeover

thermostat. Day thermostat setpoints the control the heating

and cooling operation. The Mark IV/AC control system is also

set up for load shed and shutdown operation on receipt of a

“grounded” signal to the “L” and “E” terminals, respectively,

on the low voltage terminal strip. See Figure 29.

The P and C terminals of the Mark IV/AC board are used

for pump restart. These terminals pass a voltage signal

whenever the unit compressor is turned on. This signal is

detected by a pump restart relay board providing an N.O. or

N.C. set of contacts for heat pump loop circulation pump

control. When used with the Loop Water Controller, the relay

operation accommodates turning off circulation pump con-

trol. When used with the Loop Water Controller, the relay

operation accommodates turning off circulation pumps dur-

ing unoccupied periods with a safety override dependent on,

at minimum, one WSHP's need. The P and C terminals may

be “daisy-chained” between 200 units. See page 19.

To activate the unoccupied mode for units on the same clock schedule, a single wire can be

“daisy-chained” between units and simply grounded through the time clock contacts. The

same system can also be done to activate the load shed and emergency shutdown modes

by running additional wires between units to ground.

Unit #1 Unit #2

Time Clock

Ground

Figure 29.

Additional

Units

Unit #3

* In heating mode only.

14-Position Terminal Strip

Pin Designation Description

1CTransformer ground (Ovac)

2RTransformer supply (24vac)

3V-DC power connection

4PPump request output

5A Alarm fault output

6UUnoccupied input

7LLoad shed input

8ERemote shutdown input

9F+DC power connection

10 Y1 Occupied cooling mode input

11 W1 Occupied heating mode input

12 G Fan only input

13 W2 Unoccupied heating mode input

14 O Tenant override input

Mark IV/AC Sequence of

Operation

Page 16 of 24 / IM 407

Read Outputs

Check Timers

Pres. Sw ?

Brown Out ?

Low Temp Sw ?

Lo Shed ?

N S B ?

Cond. Overflow?

R - W 1 ?

R -Y 1 ?

Stop Comp.

Flash Red LED

Stop Fan

Flash Green LED

Stop Comp.

Htg Mode?

Stop Comp.

Flash Yellow L E D

Stop Comp.

Turn On Red LED

R - W 2 ?

Start Comp.

Cooling Mode

Turn On Yellow LED

Stop Comp.

Reversing Valve On

Time Delay

Start Comp.

Yes

General Use and Information

The Mark IV/AC control board is provided with three drive terminals,

R(24vac), F(24vdc), and C(Ovac) that can be used by the end user to

drive the thermostat inputs (G, Y1, W1, and W2) and control inputs

(U, L, E, and O). Any combination of a single board drive terminal (R,

F, or C) may be used to operate the Mark IV/AC boards control or

thermostat inputs. However, only one drive terminal (R, F, or C) can

be connected to any individual input terminal or damage will occur.

Some of the control inputs are used within the Water Source Heat

Pump and not accessible to the end user. For example, HP, LT, and

COF are not available for use by the end user.

Typically the Mark IV/AC board’s R(24vac) terminal is used to drive

the board’s thermostat inputs and control inputs by connecting it to

the R terminal of an industry standard thermostat. The control

outputs of the standard thermostat are then connected to the Mark

IV/AC board thermostat inputs and control inputs as needed. Any

remaining board input(s) may be operated by additional thermostat

outputs or remote relays (dry contacts only).

All Mark IV/AC board inputs must be operated by dry contacts

devices (Triacs) may be used to operate Mark IV/AC board inputs.

No outside power sources may be used to operate Mark IV/AC

board inputs.

Note: The fault output is energized when no faults exist. The fault output is

de-energized during faults and when unit power is off.

Using Drive Using Drive Using Drive

Terminal R (24vac) Terminal F (vdc) Terminal C (ground)

De-energized Energized De-energized Energized De-energized Energized

Place the Meters

Place the Meters Place the Meters Place the Meters

Red (+) Lead on

on Black (-) Lead Black (-) Lead Black (-) Lead

Input to be

on C on V on R

checked

U, L, E, Y1, W1,

10 to 22 to

0vdc

30 to 10 to 22 to

G, W2, O 14vac 26vac

33vdc

14vac 26vac

LED Status and Fault Output Status

Board Status LED’s Fault Output

Mode Yellow Green Red Terminal A

Occupied Off On Off Energized

Unoccupied On On Off Energized

Load Shed Off Off On Energized

Condensate Overflow On Dim Off De-Energized

High/Low Pressure Fault Off Off Flash De-Energized

Low Temperature Fault* Flash Off Off De-Energized

Brownout Off Flash Off De-Energized

Emergency Shutdown Off Flash Off De-Energized

*in heating mode only

Remote Reset of Manual Lockouts – The Remote Reset feature

provides the means to remotely reset automatic lockouts generated

by high-pressure and/or low-temperature (in heating) faults. When

the Mark IV board is in automatic lockout due to one of these faults,

and the cause of the fault condition has been alleviated, energizing

the O-terminal for 10 seconds or more will force the Mark IV board

to clear the lockout. A unit power cycle can also be used to clear an

automatic lockout if the conditions causing the fault have been

alleviated.

Fault Retry To Minimize Nuisance Trips – The Fault Retry feature

helps to minimize nuisance trips of automatic lockouts caused by

high-pressure and/or low-temperature (in heating) faults. This feature

clears faults the first two times they occur within a 24-hour period and

triggers an automatic lockout on the 3rd fault. The retry count is reset

to zero every 24 hours.

IM 407 / Page 17 of 24

Thermostat Connection Diagrams

Mark IV/AC Units – Unit Sizes 007 to 060

Non-Programmable Electronic Thermostat (P/N 668054201)

7-Day Programmable Electronic Thermostat (P/N 107095901)

Includes Thermostat and Wall Plate.

Refer to the installation, operation &

application guide (LIA217) for thermostat

107095901 installation details

Optional Remote Sensor (P/N 667720401)

1. Remove cover from remote sensor housing.

2. Select an appropriate location for mounting the remote

sensor.

3. Mount remote sensor unit using hardware provided.

4. Install two strand shielded wire between remote sensor

and thermostat. Shielded wire must be used.

Do not run remote sensor wire in conduit with other wires.

• Wire 1 should run between the S1 terminal on the

thermostat and the S1 terminal on the remote sensor

• Wire 2 should run between the S2 terminal on the

thermostat and the S2 terminal on the remote sensor

• Connect the shielding of the wire to the S2 terminal on

the thermostat

5. Disable the main sensor (R12) on the thermostat by

cutting it from the circuit board.

Cut R12 from

circuit board

Remote Sensor

Thermostat

Wire 1

Wire 2

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit1)

OW2GW1Y1 F E L U A P V R C

RCW1Y1 W2 Y2 G

Thermostat Terminals

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit1)

OW2GW1Y1 F E L U A P V R C

RCW1Y1 W2 Y2 G O

Thermostat Terminals

Override (Optional)

Includes Thermostat and Wall Plate.

Refer to the installation, operation &

application guide (LIA204-4) for

thermostat 668054201 installation details

Page 18 of 24 / IM 407

Multiple Unit Control Panel for Mark IV

Up to 3 Units (Part No. 056794201)

The multiple unit control board is an accessory used when you

need to control up to 3-units from a single thermostat. The

board is typically mounted in the unit control box closest to the

thermostat. A maximum of 2 boards may be used together if up

to 6-units must be connected and controlled from a single

thermostat.

The multiple unit control board is an accessory used when you

need to control up to 2-units from a single thermostat. The board

is typically mounted in the unit control box closest to the

thermostat. The "G", "W", "Y", "C", and "L" connections are

short flying leads pre-attached to the board. A maximum of 3

boards may be used together if up to 4-units must be connected

and controlled from a single thermostat.

This version of the board uses VDC relays and should not be

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GWYR C

WSHP Mark IV/AC Board Low Voltage Terminal Strip

Multiple Unit

Control Panel

TB3

TB2

TB1

TB4

RCW1Y1 W2 Y2 G

Thermostat Terminals

This version of the board uses VAC relays and should not be

used in combination with any other accessories or equipment

that require VDC connections to the "G", "W1", or "Y1" terminals

(i.e. Boilerless System Kit).

The multiple unit control board provides the components nec-

essary to protect the Mark IV/AC board from electrical damage

that may occur when using standard off-the-shelf relays.

Up to 2 Units (Part No. 106059801)

used in combination with any other accessories or equipment

that require VAC Connections to the "G", "W1" or "Y1" terminals

(i.e. Boilerless System Kit). Do not use the unoccupied (U-

terminal) feature with the multiple unit control board.

The multiple unit control board provides the components nec-

essary to protect the Mark IV/AC board from electrical damage

that may occur when using standard off-the-shelf relays.

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Multiple Unit

Control

Panel

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

GWY C L

RCW1Y1 W2 Y2 G

Thermostat Terminals

IM 407 / Page 19 of 24

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

Options on Mark IV/AC Units

Motorized Valve & Relay for Unit Sizes 007 to 060

The auxiliary relay is designed to interface external equip-

ment with the Mark IV/AC board. The auxiliary relay has been

provided with the components necessary to protect from

electrical damage that may occur to the Mark IV/AC board

when using standard off-the-self relays. The auxiliary relay

can be used to provide fault signals, unit operation signals,

or to provide a means for remote equipment to control the

Mark IV/AC board. The orange, yellow, and white connec-

tions are short flying leads pre-attached to the board. The

diagrams shown are some connection examples.

Auxilliary Relay (P/N 106059701)

Wired as shown below the motorized valve will open on

a call for compressor operation. Valves for unit sizes

007 to 019 are

⁄2" power-open spring-return, while unit

sizes 024 to 060 are

⁄4" power-open spring-return.

Other thermostat combinations may be used. Valve and

auxiliary relay are purchased separately.

Note: The wiring shown below can only be used when the “P” terminal

is not being used as a pump restart signal to other equipment. If the

“P” terminal must be used as a pump restart signal to other equipment,

then wire the auxiliary relay’s yellow wire to “Y1”, white wire to “W1”,

and orange wire to “C”, then the valve will open on a call for occupied

heating or cooling from the thermostat.

Black to 6

White to 1

Plug

Pins,

Female

Conduit

Anti-Short

Bushing

Connector

Valve

36" (915 mm)

Lead Length

Operation: In this example the

auxiliary relay contacts can be

used to indicate a fault

condition. With the auxiliary

relay connected as shown, the

normally open contacts will

close during a fault condition.

Operation: In this example the

auxiliary relay contacts can be

used to signal WSHP fan

operation to another device. In

this example when the

thermostat energizes the “G”

terminal the auxiliary relay

normally open contacts will

close.

Operation: In this example the

auxiliary relay is used to

interface other control devices

to the Mark IV/AC board. Using

the Orange (-) and White (+)

wires, and 24vac or 24vdc,

another device could be used

to start and stop the WSHP

heating sequence.

P/N 060977401 - 1/2" Valve Kit

P/N 060977301 - 3/4" Valve Kit

P/N 859004354 - Valve Relay Kit

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

WSHP Mark IV/AC Board Low Voltage Terminal Strip

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

631

Time Clock

(by others)

Daisy-chain to

additional Mark IV/AC

board “U” terminals

Page 20 of 24 / IM 407

Boilerless System Kit (BSK)

P/N 062522201 for Sizes 007 to 042 & P/N 062522204 for Sizes 048 to 060

The BSK option for use with the Mark IV/AC control board

provides the capability to control a remote duct heater. The

duct heater must be provided with a low voltage control

circuit that only requires a set of dry contacts for operation.

The contacts shown on the Boilerless System board (termi-

nals 1, 2, and 3) are used to control the remote duct heater,

the N.O. contacts will close on a call for duct heater heat.

POT1 provides a means to manually adjust the water tem-

perature setpoint (adjustment range is 43

F to 60

F). The

The BSK field installed kits include the sheet metal enclosure

with cover, wire harness, boilerless system board, auxiliary

relay, and water temperature sensor. When used, one BSK is

required for each unit. To use the BSK kit you attach the sheet

metal enclosure to the unit as shown, route the 4-wire

harness through knockouts and connect to the Mark IV/AC

board, mount and connect and insulate the water tempera-

ture sensor on the water supply line, and then connect the

duct heater control contacts to the duct heater control

circuit.

9.66

(245 mm)

(007 – 042)

14.50

(368 mm)

(048 – 060)

6.5 (165 mm) (007 – 042)

4.12 (105 mm) (048 – 060)

1.75

(44.5 mm)

If night setback (U-terminal) is used, the duct heater will

respond to the occupied W1 thermostat signal. The load

shed input (L-terminal) cannot be used for other control

functions when being used with the BSK.

The BSK is a DC voltage device, when the BSK is used the

thermostat must be wired for VDC operation.

WSHP Mark IV/AC Board Low Voltage Terminal Strip

Auxiliary Relay

Orange

Yellow

White

12345

GR GR

Normal

Override

Pot 1

Boilerless

System

Board

43 Ohm

4-pin

Plug

Water

Temperature

Sensor

Wire Ends to be Field

Connected to the

Mark IV/AC Board

Signal to remote

duct heater

control circuit

Normal/Override switch provides a means to manually force

electric heat to always be used in place of heat pump heat

when in the override position (default position is normal - heat

pump heat).

When the water temperature drops below the value of POT1,

then the duct heater will be used instead of heat pump heat

on a call for heat from the low voltage thermostat (not

included).

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Category: Split-system air conditioners

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