McQuay LME Installation & Maintenance Data

Brand: McQuay

Model: LME

Category: Air compressors

Type: Installation & Maintenance Data

This manual is also suitable for

Installation & Maintenance Data IM 439-15

Group: WSHP

Part Number: 106581103

Date: June 2006

Large Vertical Water Source Heat Pumps

6 thru 25 Tons

Models LDD, LDE, LDL, LDS, LME, LMH, LML, LMS

Page 2 of 24 / IM 439

Model Nomenclature

W LDD 1 070 D 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

070 = 70,000

108 = 108,000

121 = 121,000

180 = 180,000

215 = 215,000

290 = 290,000

etc. . .

Coil Options

(None)

Voltage

D= 208-60-3

H= 230-60-3

K= 460-60-3

L= 575-60-3

N= 380-50-3

McQuay Product Identifiers

LDD = Std. Large Vertical/DDC Controls/Std. Range/Less Board LME = Std. Large Verical/Mark IV/Ext. Range

LDE = Std. Large Vertical/DDC Controls/Ext. Range LMH = High Static Large Vertical/Mark IV/Std. Range

LDL = Std. Large Vertical/DDC Controls/Ext. Range/Less Board LML = High Static Large Vertical/Mark IV/Ext. Range

LDS = Std. Large Vertical/DDC Controls/Std. Range LMS = Std. Large Vertical/Mark IV/Std. Range

Contents

Model Nomenclature .................................................... 2

Transportation and Storage ......................................... 2

Installation.................................................................. 3-6

Piping ............................................................................ 7

Cleaning and Flushing System ..................................... 8

Start-up ...................................................................... 8-9

Operating Limits ........................................................... 9

Electrical Data ............................................................... 9

Typical Wiring Diagrams ........................................ 10-13

Typical Mark IV/AC units ................................. 10-11

Typical MicroTech units .................................. 12-13

Unit Operation ............................................................ 14

Mark IV Sequence of Operation ................................. 15

Thermostat Connections ............................................ 16

Miscellaneous Options on Mark IV Units .............. 17-20

Field Installed Options on MicroTech Units ................ 21

Troubleshooting WSHP .............................................. 22

Maintenance ............................................................... 23

IM 439 / Page 3 of 24

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.

Sharp edges are a potential injury hazard. Avoid contact with

them.

Transportation and Storage

Upon receipt of the equipment, check unit for visible dam-

age. 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 unit must be in the “up” position.

In the event that elevator transfer makes upended position-

ing unavoidable, absolutely ensure 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 sheltered from rain, snow, etc. High or low tempera-

tures naturally associated with weather patterns will not

harm the conditioners. Excessively high temperatures 140°F

(60°C) may deteriorate certain plastic materials and cause

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

may experience operational problems.

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 shipping label for any specific tagging numbers

indicated per request from the installing contractor. At this

time the voltage, phase and capacity should be checked

against the plans.

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

will be installed in the correct location.

4. After removing the packaging material, remove unit from

the skid.

5. Before installation, check the available dimensions versus

the dimensions of the unit.

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

condensate drain piping, and electrical wiring. The loca-

tions of these items are clearly marked on submittal

drawings.

7. The installing contractor will find it beneficial to confer with

piping, sheetmetal, ceiling and electrical foremen together

before installing any conditioners.

Note: Check the unit name plate for correct voltage with the

plans before installing the equipment. Also, make sure

all electrical ground connections are made in accor-

dance with local code.

8. We recommend that the contractor cover the conditioners

with plastic film to protect the machines during finishing of

the building. This is important if spraying fireproofing

material on bar joists, sandblasting, spray painting and

plastering operations have not been completed.

Control Box

Location

Piping

Location

Fan Motor

24"

(610 mm)

Side B

Side A

24" (610 mm)

Figure 1. Service clearance

1. A 24" (610 mm) minimum clearance is required on the

return air, control box and piping sides. However, a 36"

(914 mm) clearance allows for easier serviceability.

2. A 12" (305 mm) minimum clearance is required on Side

A to gain access to panel to remove locking collar for shaft

removal.

3. A 6" (152 mm) clearance is required on Side B to remove

screws holding top panel.

4. Top clearance is required for fan shaft removal.

5. Some codes dictate a 60" (1524 mm) clearance above

the control box which could be violated with a ducted

return. Check your codes.

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 con-

nections

(see Figure 1 for service clearance details)

2. The contractor should make sure that access has been

provided including clearance for 2" (51 mm) thick filter brack-

ets, duct collars and fittings at water and electrical connec-

tions.

3. Allow adequate room around the unit for a condensate trap.

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

room. Generally, the unit is located in a separate room with

the non-ducted return air facing the return air intake. Alter-

natively, the unit can have a ducted return air.

5. It is recommended that the unit be located on vibration iso-

lators to reduce any vibration

(see Figure 3)

6. If optional field installed controls are required (Boilerless

System), space must be provided for the enclosure to mount

on the side of the unit.

CAUTION

IMPORTANT

Page 4 of 24 / IM 439

Vibration Isolation

For minimum sound and vibration transmission, it is recom-

mended that the unit be mounted on vibration isolators.

Holes are provided in the bottom panel to facilitate con-

nection of isolators

(see Figure 3 for hole locations)

Isolators supplied by the manufacturer are the type shown

in Figures 4 and 5. Four white isolators are used for single

compressor units and six green isolators are used for dual

compressor units. The holes in the bottom of the unit allow for

⁄

" (10 mm) bolt to be secured to the isolator.

Figure 3. Isolator

Figure 4. Single compressor unit — vibration isolators

Figure 5. Dual compressor unit — vibration isolators

" (10 mm) TAP

" (11 mm) dia.

" (64 mm)

" (114 mm)

" (140 mm)

" (61 mm)

Figure 2. Side view from piping end

Each unit is shipped with a filter bracket for side filter

removal.

Two fan discharges and piping arrangements are available.

With the return air side defined as the “front” of the unit, the

water piping and electrical power connections may be right-

hand (side) or left-hand. The main control panel is located in

the center of the unit, lower section under the return air filter.

Unit sides opposite the control panel and opposite the piping

side may be up against walls and still allow for service and

maintenance through the remaining access panels.

Fan Motor

Control Box Location

Piping

Unit Arrangement

Filter Access

3" (76 mm)

(715 mm)

(1390 mm)

(765 mm)

2" (51 mm)

" (83 mm)

(2042 mm)

(1021 mm)

" (83 mm)

(6)

" (10 mm) holes

2" (51 mm)

3" (76 mm)

(4)

" (11 mm) holes

" (11 mm)

" (6 mm)

(51 mm)

Section A-A

IM 439 / Page 5 of 24

Air Balancing

All units are supplied with a variable pitch motor sheave to aid

in airflow adjustment. They are typically set at the low end of

the rpm range for field adjustment to the required airflow.

When the final adjustments are complete, the current

draw of the motors should be checked and compared to the

full load current rating of the motors. The amperage must not

exceed the service factor stamped on the motor nameplate.

Upon completion of the air balance, it is a common

industry recommendation that the variable pitched motor

sheave be replaced with a properly sized fixed sheave. A

matching fixed sheave will provide longer belt and bearing

life and vibration free operation. Initially, it is best to have a

variable pitched motor sheave for the purpose of air balancing,

but once the balance has been achieved, fixed sheaves

maintain balancing and alignment more effectively.

Adjustment (See Figure 6)

1. All sheaves should be mounted on the motor or driving

shaft with the setscrew “A” toward the motor.

2. Be sure both driving and driven sheaves are in alignment

and that shafts are parallel.

3. Fit internal key “D” between sheave and shaft, and lock

setscrew “A” securely in place.

Adjusting:

1. Loosen setscrews “B” and “C” in moving parts of sheave

and pull out external key “E”. (This key projects a small

amount to provide a grip for removing.)

2. Adjust sheave pitch diameter for desired speed by open-

ing moving parts by half or full turns from closed position.

Do not open more than five full turns.

3. Replace external key “E” and securely tighten setscrews

“B” over key and setscrews “C” into keyway in fixed half of

the sheave.

Figure 6.

Figure 7. Drive belt adjustment

“E”

“B”

“D”

“C”

“A”

Single Groove

Key “E” projects to

provide a grip for

removing.

t= C

–

D-d

√

()

Where:

t= Span length, inches (mm)

C= Center distance, inches (mm)

D= Larger sheave diameter, inches (mm)

d= Smaller sheave diameter, inches (mm)

h= Deflection height, inches (mm)

Note: The ratio of deflection to belt span is 1:64.

Deflection

Force

Span Length (t)

4. Put on belts and adjust belt tension to 4 lbs. ± 0.7 lbs.

(18 ± 3N) for a

⁄2" to

⁄4" (13 mm to 19 mm) belt deflection

height.

5. To determine the deflection distance from normal position,

use a straightedge or stretch a cord from sheave to sheave

to use as a reference line. On multiple-belt drives an adjacent

undeflected belt can be used as a reference.

6. Future adjustments should be made by loosening the belt

tension and increasing or decreasing the pitch diameter

of the sheave by half or full turns as required. Readjust belt

tension before starting drive.

7. Be sure that all keys are in place and that all setscrews are

tight before starting drive. Check setscrews and belt tension

after 24 hours service.

8. When new V-belts are installed on a drive, the initial

tension will drop rapidly during the first few hours. Check

tension frequently during the first 24 hours of operation.

Subsequent retensioning should fall between the mini-

mum and maximum force.

Page 6 of 24 / IM 439

Duct Collar Side

Duct

Collar

Filter

Rack

Ductwork and Attenuation

Discharge ductwork is normally used with these conditioners.

Return air ductwork may also be required but will require field

installation of a return air duct collar.

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 flex-

ible connector at the unit, a transition piece to the final duct

size, a short run of duct, an elbow without vanes and a trunk

duct tee’d into branch ducts with discharge diffusers as shown

in Figure 10. Transition piece must not have angles totalling

more than 30 degrees or severe loss of air performance can

result.

All units have multiple fan outlets. A single duct can en-

close all the openings as shown in Figure 10; however, the

preferred method for minimum static pressure loss would be

individual ducts at each outlet connected to a larger duct down-

stream.

For minimum noise transmission, the metal duct material

should be internally lined with acoustic fibrous insulation.

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 adjacent to the return

air of the conditioner. Typically, the equipment room becomes

the common return air plenum.

Do not insert sheetmetal screws directly into the unit cabi-

net for connection of supply or return air ductwork, especially

return air ductwork which can hit the drain pan or the air coil.

Ventilation Air

Outside air may be required for ventilation. The temperature

of the ventilation air must be controlled so that mixture of out-

side air and return air entering the conditioner does not ex-

ceed conditioner application limits. It is also general practice

to close off the ventilation air system during unoccupied peri-

ods (night setback).

The ventilation air system is generally a separate build-

ing subsystem with distribution ductwork. Simple introduction

of the outside air into each return air plenum chamber rea-

sonably close to the conditioner air inlet is not only adequate,

but recommended. Do not duct outside air directly to the con-

ditioner inlet. Provide sufficient distance for thorough mixing

of outside and return air

(see Operating Limits on page 9).

Optional Duct Collar and 2" (51 mm)

Filter Rack

The optional duct collar kit is used to facilitate connection of

return air duct to the unit. The duct collar kit can be used in

conjunction with the standard 1" (25 mm) thick filter rack or

the optional 2" (51 mm) filter rack.

The 2" (51 mm) filter rack facilitates the installation of 2"

(51 mm) thick filters for side removal. The 2" (51 mm) filter

rack replaces the existing 1" (25 mm) filter rack and does not

require the use of the optional return air duct collar.

The kits are installed as follows:

1. Remove all filters, filter racks and brackets. Save all

screws. Discard bracket end.

2. Attach top duct collar in conjunction with top filter rack

with truss head screws.

3. Attach bottom duct collar and filter rack.

4. On single compressor units, attach two flanges using four

(4) #8 truss head screws provided.

5. Attach center support in original location.

6. Locate and attach center filter racks using screws pro-

vided.

7. Attach duct collar sides using eight (8) #10 sheetmetal

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 of dielectric fittings.

Figure 8. Assembly detail

Center Support

Chassis

Door End

Duct Collar Side

Center Filter Racks

Side Flanges

Top Duct Collar

Top Filter Rack

Filters

Figure 9.

IM 439 / Page 7 of 24

1. All units are recommended to be connected to supply and

return piping in a two-pipe reverse return configuration. A

reverse return system is inherently self-balancing and re-

quires only trim balancing where multiple quantities of units

with different flow and pressure drop characteristics are

connected to the same loop. A simple way to check for

proper water balance is to take a differential temperature

reading across the water connections. To insure proper

water flow, the differential should be 10°F to 14°F (5°C to

8°C) in the cooling mode of operation.

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

ceptably, but proper water flow balancing is more difficult

to achieve and maintain, and may require flow control

devices.

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 pip-

ing can also be brought directly to the unit although it is

not recommended since no vibration or noise attenuation

can be accomplished. The hard piping must have unions

to facilitate unit removal

(see Figure 10 for typical piping

setup)

Piping

Flexible

Connector

Transition

Duct

Main

Duct

Branch

Duct

Trunk Duct

Flexible Hose

with Brass

Pipe Fittings

Supply

Return

Balancing

Valve with

Close-off

Condensate

Figure 10.

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.

4. Supply and return shutoff valves are required at each con-

ditioner. 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.

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

ing 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 balancing.

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

unit is supplied with a FPT threaded fitting.

7. The condensate disposal piping must have a trap and the

piping must be pitched away from the unit not less than

⁄

" per foot (21 mm per meter). Generally, the condensate

trap is made of copper. A complete copper or PVC conden-

sate system can also be used. Union fittings in the copper

lines should be applied to facilitate removal.

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

nection 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 of dielectric fittings.

Cleaning and Flushing

System

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 con-

ditioner location. This will prevent the introduction of dirt

into the unit. Additionally, pressure operated valves only

open when the compressor is operating

(see Figure 11)

Figure 11.

Return Runout

Supply Runout

Mains

Rubber Hose

Runouts Initially

Connected Together

CAUTION

Page 8 of 24 / IM 439

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

connection with all air vents open. After filling, vents should

be closed.

The contractor should start main circulator with pres-

sure reducing valve makeup open. Vents should be

checked in sequence to bleed off any trapped air to as-

sure 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. Drain 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 con-

tinue 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 re-

turn 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 sim-

ply 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 anti-

freeze may also be added at this time. Use commercial

grade anti-freeze designed for HVAC systems only. Do

not use automotive grade anti-freeze.

6. Set the system control and alarm panel 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 circulat-

ing 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.

Start-up

1. 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 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 variable pitch motor sheaves. Reset for

correct airflow.

4. Set thermostat to Cool. If the thermostat is an automatic

changeover type, simply set the cooling temperature to

the coolest position. On manual changeover types addi-

tionally select Cool at the system switch.

Again, many conditioners have time delays which

protect the compressor against short cycling. After a few

minutes of operation, check the discharge grilles for cool

air delivery. Measure the temperature difference between

entering and leaving water. It should be approximately

⁄2 times greater than the heating mode temperature

difference. For example, if the cooling temperature dif-

ference is 15°F (8°C), the heating temperature difference

should have been 10°F (5°C).

Without automatic flow control valves, a cooling tem-

perature 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) degree difference in cooling.

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

changeover type, set system switch to the Auto position

and depress the heat setting to the warmest selection.

Some conditioners have built-in time delays which pre-

vent 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 6.6°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), the airflow rate is probably inadequate.

If the water temperature difference is less than 6°F

(3.3°C) degrees, the water flow rate is excessive. If the

water temperature difference exceeds 12°F (6.6°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.

Cleaning and Flushing System (Continued)

IM 439 / Page 9 of 24

Operating Limits

Environment

This equipment is designed for indoor installation only. Shel-

tered locations such as attics, garages, etc., generally will

not provide sufficient protection against extremes in tem-

perature and/or humidity, and equipment performance, reli-

ability, and service life may be adversely affected.

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.

Additional Information

1. All units

Unit will start up in an ambient of 40°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 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.

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. Each unit is supplied

with a 3-lug terminal block in the main control for three-

phase main power. Multiple knockouts on the sides of the

unit facilitate conduit connections on the unit for line and

low voltage. A disconnect switch near the unit is required

by code. Power to the unit must be sized correctly and be

fused with Class RK5 dual element fuses.

Minimum and Maximum Voltage

Nameplate 208/60/3: Min. 187 volts, Max. 229 volts

Nameplate 230/60/3: Min. 207 volts, Max. 253 volts

Nameplate 460/60/3: Min. 414 volts, Max. 506 volts

Nameplate 575/60/3: Min. 515 volts, Max. 632 volts

Nameplate 380/50/3: Min. 360 volts, Max. 418 volts

Three-phase system unbalance should not exceed 2%.

Voltages listed are to show voltage range. However, units

operating with overvoltage and undervoltage for extended

periods of time will experience premature component failure.

All UNITS

Cooling Heating

Table 1. Air and water limits

Min. Ambient Air 40°F/5°C40°F/5°C

Normal Ambient Air 80°F/27°C70°F/21°C

Max. Ambient Air 100°F/38°C85°F/29°C

Min. Ent. Air

➀➁

50°F/10°C40°F/5°C

Normal Ent. Air, 80/67°F70°F

db/wb 27/19°C21°C

Max. Ent. Air, 100/83°F80°F

db/wb

➀➁

38/28°C27°C

Table 2. Water enthalpy

Cooling Heating Cooling Heating

Min. Ent. Air

➀➁

55°F/13°C55°F/13°C40° F/5°C40°F/5°C

Normal Ent. Air 85°F/29°C70°F/21°C85°F/29°C70°F/21°C

Max. Ent. Air

➀➁

110°F/43°C90°F/32°C 110°F/43°C90°F/32°C

CAUTION

Page 10 of 24 / IM 439

Ty pical Wiring Diagrams

Figure 12. Typical Mark IV/AC unit — single compressor

L3 L2

Junction

Box

Term

Board

Comp

GND

Crankcase

Heater

Fan

Motor

GND

Common

Comp

Fan

Mark IV/AC

Board

Compressor

Contactor

Breaker

(Optional)

OR 230V

RD 208V

BK/RD 460V

GND

Xformer

REV Valve Solenoid

COF

High

Press

Switch

Low

Press

Switch

Low

Temp

Switch

Ring

Terminal

(Condensate

Overflow)

Thermistor

GOFELUAPVRC

Electric

Expansion

Valve

061093503 Rev. A

IM 439 / Page 11 of 24

Figure 13. Typical Mark IV/AC unit — dual compressor

COMMON

COMP

FAN

FELUAPVRC

211

COMMON

COMP

FAN

FELUAPVRC

211

Fan

Motor

Electric

Expan Valve

Optional

Crankcase

Heater

Compr. 2 Compr. 1

Chassis Control

RD7

BK12

RD6

BK92

BK93

Compr.

Cont. 1

Compr. Cont. 2

BK82

BK83

}

YE14

Optional

Positive

Staging

Relay

GR/YE

YE13YE13

BK11

WH56

WH57

WH55

Circuit 2

Thermistor

Electric

Expan Valve

WH46

WH47

WH45

Low Temp

Circuit 1

Circuit

High Press

Switch

Low Press

Switch

Reversing Valve

Solenoid

(not required on cooling only)

High Press

Switch

Low Press

Switch

BR53

Low Temp

RD54

BR52

BK51

BL50

BL40

BK41

BR43

RD44

BR42

BK51

BL50

BL40

BK41

Condensate

Overflow

Sensor

BK30

BK49

RD48

BK59

RD58

BR87

RD88

PK89

WH85

WH86

BK83

BL18

YE13

BK11

BK82

BK31

YE8

BK4

YE14

BK12

BK92

BK32

YE9

BK5

BK93

BL17

BK10

RD208

OR240

RD208

OR240

WH16

YE28

YE23

WH16

BK34

BL19

Control 1

BR42

BR43

BK41

BK40

BK30

BK29

WH66

BL50

BK51

COF

BK24

BK25

Red

Control 2

BR52

BR53

COF

BK20

BK19

WH56

PK21

YE23

WH64

RD22

WH55

BK59

RD59

BR53

BK51

BL50

BK29

PK89

BR87

RD88

WH46

PK26

YE28

WH65

RD27

WH45

BK49

RD48

WH15

BL17

BK33

GND

Breaker 3A (optional)

Field

Line

Voltage

WH15

YE3

BK10

RD2

BK1

BK34

BK33

YE3

YE8

YE9

RD7

RD2

RD6

BK4

BK1

BK5

RD27

RD22

Page 12 of 24 / IM 439

Figure 14. Typical MicroTech unit — single compressor

LEGEND

Component

Wire Connector

Thermistor

Heater Crankcase Heater

Optional Wiring

LP1 Low pressure Switch

HP1 High Pressure Switch

LT1 Low Temperature Switch

RV Reversing Valve Solenoid

M2 Compressor Contactor

M1 Fan Starter

R1 & R2 Relay

V1 Expansion Valve

T1 & T2 Transformer

TB Terminal Block Connection

> >

L2L1 L3

Gnd.

Lug

T2 T3

123

GR/Y

Fan

Mtr.

Compr.

Mtr.

( Ext. Rng. Only)

Heater

BK/RD 460V

OR 230V

RD 208V

BK 575V

VT 400V

J2J1

MicroTech

Controller

1234567

111098765432

23457891011

Low Temp. SIG

Lo Press SIG

Condensate

Lo Temp. SRC

RV Out

Comp Com

Comp Out

Fan Com

Fan Out

24VAC

24V Gnd

Discharge Air Com

Discharge Air In

Water Out Com

Water Out In

Lo Press SRC

Hi Press SRC

RV Com

Aux Module SEL 2

Aux Module SEL 1

Aux Module DC Com

Remote D1 SRC

Remote D1 SIG

Spare Relay NC

Spare Relay Com

Spare Relay NO

RM Sensor LED

Tenant Override

RM Sensor In

RM Sensor Com

Lon Talk

24VAC Com

Aux Module DC +

Aux Module CLK

Aux Module RCV

Aux Module XMT

LT1

LP1

Condensate

Overflow

HP1

234567891011121314 6

Auxiliary Module

(Optional)

Terminal Board #2

Circuit

Breaker

9190

24V

T1 (50VA)

Disch.

Air

Water

Out

Terminal Board #1

(optional)

IM 439 / Page 13 of 24

Figure 15. Typical MicroTech unit — dual compressor

LEGEND

Component

Wire Connector

Thermistor

Heater Crankcase Heater

Optional Wiring

V1 & V2 Expansion Valve

R1, R2 & R3 Relay

M2 & M3 Compressor Contactor

T1 & T2 Transformer

RV1 & RV2 Reversing Valve Solenoid

LP1 & LP2 Low pressure Switch

HP1 & HP2 High Pressure Switch

LT1 & LT2 Low Temperature Switch

M1 Fan Starter

TB Terminal Block Connection

>>>>

Gnd Lug

PB1

123

Fan

Mtr.

GR/Y

Compr.

Mtr.

Compr.

Mtr.

BK/RD 460V

OR 230V

RD 208V

BK 575V

VT 400V

CKT1

CKT 2

Circuit

Breaker

9695

RV2

LP2

LT2

J10J11J4

Auxiliary

Module

MicroTech

Controller

1234 1234

J2 J1

Disch

Air

Water

Out

Condensate

Lo Temp SRC

Lo Temp SIG

Lo Press SIG

Lo Press SRC

Hi Press SIG

RV Com

RV Out

Comp Com

Comp Out

Fan Com

Fan Out

24VAC

24V Gnd

Discharge Air Com

Remote D1 SRC

Remote D1 SIG

Spare Relay NC

Spare Relay NO

Spare Relay Com

RM Sensor LED

Tenant Override

RM Sensor In

Lon Talk

RM Sensor Com

24VAC Com

Lon Talk

Discharge Air Water

Water Out Com

Water Out In

Aux Module DC Com

Aux Module DC +

Aux Module SEL 2

Aux Module SEL 1

Aux Module CLK

Aux Module RCV

Aux Module XMT

RV1

HP1

Condensate

Overflow

LP1

LT1

123456789101111121314

J1 J2

78910 561

Terminal Board #2

12345 6789101112

12345678

J5 J6

234

234567

4321 4321

HP2

T1 (50VA)

L2 L3

T1 T2 T3

Heater

(Ext. Rng. Only)

Heater

(Ext. Rng. Only)

Terminal Board #1

(optional)

Page 14 of 24 / IM 439

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

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 thermo-

stat, W2 on single compressor and W3 on dual compressor

Ground

Unit

Additional

Units

Time

Clock

Unit

Unit Operation

General

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

voltage output from the low voltage terminal strip on the control

board is always 24 volts DC (direct current). Terminals C and

R on the low voltage terminal strip supply 24 volts AC power.

The unit has been designed for operation with a 24 volt

mercury bulb type wall thermostat or a microelectronic wall

thermostat selected by the manufacturer. Do not operate the

unit with any other type of wall thermostat.

Table 3.

LEDs

FAULT

INDICATION

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

Brown-out Off Flash Off On

Load Shed Off Off On Off

Unoccupied Mode On On Off Off

Unit Shutdown Off Flash Off On

*In heating mode only.

Mark IV/AC Control Units

Single compressor units have a single Mark IV/AC circuit

board and dual compressor units have two Mark IV/AC circuit

boards. The refrigerant circuits on dual compressor units

operate totally independent from each other and allow for

total independent operation of each circuit.

The Mark IV/AC circuit board has built-in features such as

random start, compressor time delay, night setback, load

shed, shutdown, condensate overflow protection, defrost

cycle, brownout, and LED/fault outputs.

The 24 volt low voltage terminal strip on each board is set

up so R-G energizes the fan, R-Y1 energizes the compressor

for cooling operation, R-W1 energizes the compressor and

reversing valve for heating operation. The reversing valve is

set up to be energized in the heating mode. The circuit board

has a fan interlock circuit to energize the fan whenever the

compressor is on if the thermostat logic fails to do so.

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

compressor operation if any one of its safety switches opens

(high pressure switch and low pressure switch). 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. 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. Table 3 shows for which functions

the fault output is “on” (sending a signal to the LED).

units; day heating and cooling operation is locked out. R-W2

energizes the compressor and reversing valve for heating

operation. Night setback operation can be overridden for two

hours by toggling the fan switch (intermittently closing the R

to O terminals) on the Deluxe Auto Changeover thermostat.

Day thermostat setpoints then control the heating and cool-

ing 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 16).

Figure 16.

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 timeclock 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.

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’s compressor is turned on. This signal is

detected by a Pump Restart Relay board (P/N 898-613703X01)

providing a 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 pumps during unoccupied periods with a safety

override dependent on, at minimum, one WSHPs need. The

P and C terminals may be “daisy chained” between 200 units

(see page 18).

IM 439 / Page 15 of 24

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

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 out-

puts of the standard thermostat are then connected to the Mark IV/

AC board thermostat inputs and control inputs as needed. Any re-

maining board input(s) may be operated by additional thermostat out-

puts or remote relays (dry contacts only).

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

ered by the control board’s power terminals. No solid state devices

(Triacs) may be used to operate Mark IV/AC board inputs. No outside

power sources may be used to operate Mark IV/AC board inputs.

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

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 allevi-

ated.

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.

Page 16 of 24 / IM 439

Thermostat Connection Diagrams

Mark IV/AC Units – Unit Sizes 070 to 121

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

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

Thermostat Terminals

Includes Thermostat and Wall Plate.

Refer to the installation, operation &

application guide (LIA204-4) for thermostat

668054201 installation details

IM 439 / Page 17 of 24

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.

Mark IV/AC Units – Unit Sizes 180 to 290

Non-Programmable Electronic Thermostat – 2 Circuits (P/N 107095901)

7-Day Programmable Electronic Thermostat – 2 Circuits (P/N 107095901)

Includes Thermostat and Wall Plate.

Refer to the installation, operation &

application guide (LIA217) for thermostat

107095901 installation details

Includes Thermostat and Wall Plate.

Refer to the installation, operation &

application guide (LIA204-4) for thermostat

668054201 installation details

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit 1)

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 (Circuit 2)

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit 1)

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 (Circuit 2)

OW2GW1Y1 F E L U A P V R C

Wire 1

Wire 2

Thermostat

Remote Sensor

Cut R12 from

circuit board

Page 18 of 24 / IM 439

Pump Restart Relay Kit P/N 061419001

Wiring Pump Restart Relay when Installed within the LWC Panel

Wiring Pump Restart Relay when Installed within a WSHP Control Box

Miscellaneous Options on Mark IV Units

Used as an option with the Mark IV/AC board, the pump

restart relay kit provides a means to alert the loop water

controller that water flow is required by a WSHP so that the

system pump can be started. This option is typically used in

installations where the pump may be shut off when there is

no need for water flow (i.e. temperature OK, etc.). Typically

only one pump restart relay kit is required per installation as

up to 200 Mark IV/AC boards can be “daisy-chained” to-

gether.

The Mark IV/AC “P” terminal is used to determine WSHP

compressor operation. Wired as shown below, when com-

pressor operation is required, the Mark IV/AC “P” terminal

will change state causing a contact closure between terminal

58 and 64 signaling the loop water control (LWC) panel to

restart the loop pump if Off.

The pump restart relay kit is typically mounted within one

WSHP or within the LWC panel, whichever is more conve-

nient, diagrams are provided below for each location. To

install the relay, remove the cover on the double-faced tape

provided on the relay and attach the relay either to the inside

of the LWC panel (adjacent to circuit breaker CB1 and

terminal block TB3) or in the WSHP control box (in a conve-

nient location), then wire as shown below.

Note: Make all wiring connections to circuit one (1) board when adding this option to a dual circuit machine.

WSHP Mark IV/AC Board Low Voltage Terminal Strip (Circuit 1)

Pump

Restart

Relay

OW2GW1Y1F E LUAPVRC

Power by

others

Daisy chain to other Mark

IV/AC board “P” and “C”

terminals

IM 439 / Page 19 of 24

To Low Voltage

Hole on Unit

Shutoff Valve

To Main System

Conduit Assembly

Motorized Valve

Assembly

Flexible Hose

Return Water Connection

Typical Motorized Valve Installation

Motorized Valve & Relay for Large Vertical Units

Wired as shown below the motorized valve will open on a

call for compressor operation. These 1-

⁄4˝ and 1-

⁄2˝ valves

are power-open power-close. Valve and auxiliary relay are

purchased separately.

P/N 061201002 - 1-1/4" Valve Kit (070-120)

P/N 061201102 - 1-1/2" Valve Kit (180-290)

P/N 061201202 - Valve Relay

Note: Wire motorized valve relay to Circuit one (1) on all dual circuit machines, sizes 180, 215 and 290, as illustrated above.

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.

Orange to 5

Pin, Male

Plug

Conduit

Anti-Short

Bushing

66" (1676 mm)

Lead Length

/4" or 1

/2"

Valve

Black to 1

Red to 2

White to 3

Yellow to 4

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

OW2GW1Y1 F E L U A P V R C

Auxiliary Relay

Orange

Yellow

White

45231

Valve

COMP Spade

Terminal (On

Circuit 1 Mark

IV/AC Board)

COMMON

Spade Terminal

(On Circuit 1

Mark IV/AC)

Compressor

Contactor

(Circuit 1)

Time Clock

(by others)

Daisy-chain to

additional Mark IV/AC

board “U” terminals

Boilerless System Kit (BSK)

P/N 062522204 for sizes 070 - 108 and 121 & P/N 0061251501 for sizes 180, 215 and 290

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

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).

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.

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, one example is

provided below. This example is for a 2-circuit WSHP, R1 is

a field supplied 24vdc relay. R1 is not required on 1-circuit

units.

Control Box

Boilerless System Kit

Page 20 / IM 439

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

OW2GW1Y1 F E L U A P V R C

Thermostat Terminals

WSHP Mark IV/AC Board Low

Voltage Terminal Strip

Strip

RCW1Y1 W2 Y2 G

OW2GW1Y1 F E L U A P V R C

WSHP Mark IV/AC Board Low

Voltage Terminal Strip

Strip

43 Ohm

Wire ends

from

Boilerless

System Kit

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Model: LME

Category: Air compressors

Type: Installation & Maintenance Data

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