McQuay Skyline IM 777-6 Unit installation

Installation and Maintenance Manual
Skyline™ Air Handler
IM 777-6
Group: Applied Air Systems
Part Number: IM 777
Date: October 2011
Models OAC/OAH 003G – 090G
®
© 2011 McQuay International
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Curb Mounting and Unit Leveling . . . . . . . . . . . . . . . 5
Assembling Sections . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shipping Sections . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panels, Frame Channels, and Doors . . . . . . . . . . . . 8
Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Frame Channel Removal . . . . . . . . . . . . . . . . . . . 8
Access Doors and Panels . . . . . . . . . . . . . . . . . . . 8
Fan Section Doors . . . . . . . . . . . . . . . . . . . . . . . . 8
Injected-Foam Insulated Panels . . . . . . . . . . . . . . 9
Field Mounting Junction Boxes and
Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dampers and Hoods . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . 10
Face and Bypass Section Mounting . . . . . . . . . . . . 11
Piping Vestibules . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water Cooling Coils . . . . . . . . . . . . . . . . . . . . . . 11
Direct Expansion Coils . . . . . . . . . . . . . . . . . . . . 11
Steam Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Heating Coils . . . . . . . . . . . . . . . . . . . . . . 14
Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Internal Isolation Assembly Adjustment . . . . . . . . . 15
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2
Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . .
Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Starting the Unit . . . . . . . . . . . . . . . . . . . . .
Fan Wheel Alignment . . . . . . . . . . . . . . . . . . . .
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . . .
Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . .
18
18
18
19
21
22
22
Service and Maintenance . . . . . . . . . . . . . . . . . . . .
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing Lubrication . . . . . . . . . . . . . . . . . . . . .
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . .
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VM and VP Variable Pitch Key Type Sheaves .
LVP Variable Speed Sheaves . . . . . . . . . . . . . .
MVP Variable Speed Sheaves . . . . . . . . . . . . .
Fan Drive Belt Adjustment . . . . . . . . . . . . . . . . .
Front Load Filter Option . . . . . . . . . . . . . . . . . . . . .
Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winterizing Water Coils . . . . . . . . . . . . . . . . . . .
Removing and Replacing Components . . . . . . . . .
Removing the Fan Section . . . . . . . . . . . . . . . .
23
23
23
23
23
24
24
25
26
28
29
29
29
30
30
30
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . 32
Service and Warranty Procedure . . . . . . . . . . . . . . 33
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Warranty Return Material Procedure . . . . . . . . . . . 33
Check, Test, and Start Procedure Form . . . . . . . . . 34
Quality Assurance Survey Report . . . . . . . . . . . . . 36
McQuay IM 777-6
Introduction
Introduction
General Information
Receiving and Handling
The system design and installation must follow accepted industry
practice as described in the ASHRAE Handbook, the National
Electric Code, and other applicable standards. Install this
equipment in accordance with regulations of authorities having
jurisdiction and all applicable codes.
1 Carefully check items against the bills of lading to verify
Installation and maintenance must be performed by qualified
personnel familiar with applicable codes and regulations and
experienced with this type of equipment. Sheet metal parts,
self-tapping screws, fins, clips, and such items inherently have
sharp edges; the installer should exercise caution.
painted steel and are inspected thoroughly before leaving
the factory. Take care during installation to prevent
damage to units.
all crates and cartons have been received. Carefully
inspect all units for shipping damage. Report damage
immediately to the carrier and file a claim.
2 Skyline air handler units are constructed of galvanized or
3 Take special care when handling the blower section. All
fans are dynamically balanced before leaving the factory.
Rough handling can cause misalignment or a damaged
bearings or shaft. Carefully inspect fans and shaft before
unit installation to verify this has not happened.
CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.
Note: Screws, bolts, etc., for assembling sections are supplied
in a bag attached to each section. All necessary
gasketing is applied in the factory for section-to-section
mounting, unless the unit has a curb ready base. Units
require caulk sealant between sections.
Nomenclature
CAH
Model
CAH = Custom modular air handler
CAC = Custom modular component
Nominal unit size
(cataloged size—nominal square foot of coil)
003, 004, 006, 008, 010, 012, 014, 017,
021, 025, 030, 035, 040, 050, 065, 080, 085, 090
Vintage of McQuay air handling unit
003 G
D
A
C
Unit cross section
C = Standard unit cross section
M = Custom size cross section
Motor location
A = Motor along side of fan housing
D = Motor down stream of belt drive
plenum fan
F = Motor on inline fan
G = Motor downstream of direct drive
plenum fan
H = Motor downstream of fan array
T = Motor behind twin fan housing
Unit type/coil position
B = Blow-through cooling coil location
D = Draw-through cooling coil location
H = Heating only
V = Vent only
M = Multizone
McQuay IM 777-6
3
Introduction
Unit Storage
Belt driven fans:
• Store on a level surface in a clean, dry location where
temperature can be controlled if possible.
• Reduce belt tension by at least 50% or remove the belts.
Remove belts if they will be subjected to temperatures
exceeding 85° F to avoid deterioration.
• Pack fan and motor bearings (unless motor bearings are
sealed) with compatible grease with the shaft stationary.
After grease has been installed, rotate shaft about 10
rotations.
• Isolate unit from shock and vibration.
• Once a month, rotate shaft a minimum of 10 revolutions.
Insure the stopped position is different than the original
position.
• Coat shafts with lubricant as needed to prevent corrosion.
• A descant bag may be hung in the interior of the unit to
minimize corrosion in humid storage environments.
• Do not clean galvanized steel surfaces with oil dissolving
chemicals. This may remove the protective coating and
accelerate corrosion.
• Do not allow coverings to trap moisture on galvanized
surfaces.
• Remove belt guard when adjusting belts
• Reduce belt tension prior to removing or installing belts.
Removing or installing tensioned belts may cause personal injury and damage to the sheaves, belts, bearings or
shafts.
• Adjustable sheaves should be opened as wide as possible
and the adjustment threads lubricated so they do not corrode.
Be careful not to put lubricant on the belt running surface
Prior to start up:
• Set screws on bearings, fan wheels, and sheaves need to be
checked for proper torque. Also check bolt torque for any
taper lock hubs either on the wheel or sheaves.
• Check sheaves for corrosion. Significant corrosion can cause
belt or sheave failure.
• Purge old grease from fan bearings while rotating the shaft
to distribute the new grease evenly and prevent bearing seal
failure.
• Correctly align and tension belts. See General Rules of
Tensioning‚ page 28.
4
McQuay IM 777-6
Mechanical Installation
Mechanical Installation
Service Clearances
Rigging
In addition to providing adequate space around the unit for
piping coils and drains, access to at least one side of the unit is
always required to allow for regular service and routine
maintenance, which includes filter replacement, drain pan
inspection and cleaning, fan bearing lubrication, and belt
adjustment. Provide sufficient space—at least equal to the
length of the coil—on the side of the unit for coil removal. See
Figure 1 for servicing space requirements.
Skyline air handlers ship as separate sections, completely
assembled, or in modules of assembled sections. The unit must
be rigged as it ships from the factory. Do not rig units after
assembly. Units are provided with a factory-installed base rail
and can be lifted using the 2" diameter lifting holes located in
the corners of each shipping section. To prevent damage to the
unit cabinetry, use spreader bars. Position spreader bars to
prevent cables from rubbing the frame or panels. Before
hoisting into position, test lift for stability and balance. Avoid
twisting or uneven lifting of unit.
Maintain at least 54" of clearance in front of electrical power
devices. Electrical power devices that are mounted on the side
of the unit typically are up to 12" deep (Figure 2).
Figure 3: Unit and Section Rigging
Figure 1: Servicing Space Requirements
4 .0 0 " b a s e r a il e x te n s io n
W id th
3 0 .0 0 "
W id th o f c o il s e c tio n
4 .0 0 "
W id th o f
fa n s e c tio n
Curb Mounting and Unit Leveling
3 0
.0 0
"
H e ig h t
Figure 2: Service Clearance for Electrical Power Devices
Do not place a Skyline unit over an open curb unless it is
equipped with a curb-ready base. Installation instructions for
mounting units on a roof curb are provided in IM 770. For a
copy, contact your local McQuay representative or visit
www.mcquay.com. Make provisions under the unit to divert
any moisture from entering the building below.
For units without roof curb mounting, place the equipment on
a flat and level surface. Where surface irregularities exist, shim
the base of the unit at one or more points along the length of
the rails to prevent distortion or sagging of the support rails.
Uneven or distorted sections cause misfit or binding of the
doors and panels and improper draining of drain pans
(Figure 4).
Figure 4: Leveling the Unit
1 2 "
5 4 "
McQuay IM 777-6
S h im s e c tio n s u n til
th e y a r e s tr a ig h t
a n d le v e l
S h im to p r e v e n t
d is to r tio n if w id th
is o v e r 1 0 8 "
5
Mechanical Installation
Assembling Sections
If the unit is shipped in more than one shipping section, rig
each section into position separately. Shipping sections are
provided with a connection splice joint attached on the leaving
air side of the shipping section that seals against the frame
channel on the entering-air side of the adjoining. The splice
joint is insulated and provides an air-tight seal between two
sections once they are assembled together. Align the splice
joint to seat into the mating gasket to provide an air seal. If the
splice joint was bent during shipping or rigging, restore it to its
original position (Figure 9). For Skyline Plus units, ensure that
the D-gasket is attached to the entering air side frame channel
(Figure 7 and Figure 10).If it dislodged during shipping,
restore it to its designed position.
c Handle units with curb-ready bases and vestibules so
the lifting bracket can be removed after the unit is
placed on the curbing.
Note: Remove the lifting bracket that projects inward over
the curbing. Save the self tapping screws. When the
adjacent section is placed in position, use self
tapping screw to secure the bases together.
Figure 6: Remove Vestibule Lifting Bracket
Shipping Sections
1 Caulk all assembly joints of the unit—Before joining the
sections, apply at least 1/4 inch diameter bead of sealant
to the mating faces of the cabinet. Use the splice joint as
a guide for applying the sealant (Figure 5).
R e m o v a b le
L iftin g B r a c k e t
Figure 5: Apply Sealant to Mating Faces
Figure 7: Fasten Bottom of Section
1 /4 " d ia m e te r
b e a d c e n te re d
in fa c e o f
c le a r a n c e
U s e S p lic e
J o in t a s a
g u id e
“D”
Gasket
2 Pull sections together to fasten. Use straps and a ratchet
to help pull the sections together securely. Apply sealant
to any gaps that may admit moisture.
3 Fasten base rails together first using the 3/8"-16 × 5"
bolts located in the splice kit provided with the unit
(Figure 7).
a To fasten two shipping sections together, four bolts
are needed (two on each side of the unit). The bolts
are run from one base rail into the other and fastened
with a nut. Complete each section bottom and top
before attaching additional sections.
3/8" x 1" Bolt and Nut
d A length of “D” gasket is attached to each section
(Figure 7). This gasket MUST be installed to the unit
base section.
b If desired, shipping sections for non curb-ready units
can be fastened together internally. To fasten
internally, run field-provided #10 sheet metal screws
or drill screws (4" long, maximum) through the
interior frame channel of one unit into the splice joint
of the neighboring section.
6
IMPORTANT
The gasket is to be installed in an arc shape with the ends
lower than the center, so that any moisture that may reach the
gasket will be drained to the outside of the unit.
McQuay IM 777-6
Mechanical Installation
e Handle units with curb-ready bases and vestibules so
the lifting bracket can be removed after the unit is
placed on the curbing.
Figure 10: D-Gasket Placement Detail (Skyline Plus Units
Only)
Note: Remove the lifting bracket that projects inward over
the curbing. Save the self tapping screws. When the
adjacent section is placed in position, use self
tapping screw to secure the bases together.
f
For certain Skyline Plus units, use the provided
section joining plates to fasten sections together.
Space them as shown in Figure 8. Using the provided
¼"-14 x 1" self tapping screws, drill screw the joining
plates into the frame channel on each section, keeping
unit sections tight together. Follow instruction
drawing included in the assembly kit.
Figure 8: Frame Channel Stiffener Plates (Skyline Plus
Units Only)
1 Check that the sealant is compressed between the mating
channels when the unit sections are joined. Touch up any
places where gaps are noted.
2 After sections are seated tightly together, slip the splice
cap over the top panel flanges. Bend the ends of the
splice cap down to secure in place (Figure 11).
3 Assemble the small splice plate at the top rail to secure
the sections together at the top. Use 5/16" bolts
(Figure 11).
Figure 11: Splice Cap and Splice Plate
S lid e S p lic e C a p o n
a n d b e n d e n d s d o w n
Figure 9: Internal Fastening
5 /1 6 - 1 8 B o lt
5 /1 6 -1 8 N u t
S p lic e
P la te
A
S p lic e C o lla r
m u s t b e a lig n e d
to s e a l to g a s k e t.
McQuay IM 777-6
7
Mechanical Installation
Panels, Frame Channels, and Doors
Panel Removal
To remove a side or top panel, remove the flat head Torx 30
fasteners along the sides of the panel. Lift off the panel after
removing all fasteners.
Fan Section Doors
Note: Opening fan section doors requires using a 1/2" socket
wrench (Figure 13), which satisfies ANSI standards and
other codes that require the “use of tools” to access
compartments containing moving parts or electrical
wiring.
CAUTION
Frame Channel Removal
Frame channels that run the length of the unit along the top can
be removed to allow access to both the side and top of the unit.
To remove the frame channel, first remove the side panel(s).
Once the side panel is off, remove the flat head Torx 30
fasteners in the corner of the frame channels. Then pull the
frame channel out the side. Remove any panel screws that are
within one inch of the of the frame since they are engaged into
the gasketed flange of the frame (Figure 12).
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.
1
Insert 1/2" socket and rotate 1/4 turn clockwise as shown in
Figure 13. If the handle is on the left side of the door, rotate
1/4 turn counterclockwise.
2
Rotate the door handle 1/4 turn clockwise and then 1/4 turn
counterclockwise to release any internal pressure or
vacuum and open the door. If the handle is on the left side
of the door, rotate the door handle 1/4 turn
counterclockwise and then 1/4 turn clockwise.
3
To prevent air leakage, tighten the door panels by adjusting
the jam nuts.
Figure 12: Removing Panel Screws
Remove any
panel screws that
engage frame
Remove panel
to remove frame
Figure 13: Opening Fan Section Door
Access Doors and Panels
For routine maintenance, access normally is obtained through
access doors or by removing side panels. Removing all flat
head fasteners along the sides of a panel allow it to be
removed.
Fan and filter sections are always provided with a service door
on one side of the unit. If requested on order, doors can be
provided on both sides of the unit. Optional service doors are
available for most section types and are provided based on
customer request.
8
McQuay IM 777-6
Mechanical Installation
Injected-Foam Insulated Panels
Skyline air handlers now are furnished with double-wall,
injected-foam insulated panels. Foam panels are stronger,
more rigid, and lighter than panels with fiberglass insulation.
The insulation R-value is improved to 13. However, foam
insulation can burn when exposed to flame or other ignition
sources and release toxic fumes. Take care in cutting and
sealing all field-cut openings in these panels.
Figure 14: Cutting/Sealing Injected-Foam Insulated Panels
Seal completely with silicone
sealant or duct seal compound
Cut hole from both sides of panel
Panel Cutting Procedure
1 Determine the number and location of holes required for
electrical conduit, piping, and control wiring as follows:
a Check that adequate space is available inside the unit
Prop 65—Substances in fuel or from fuel combustion can cause personal injury or death,
and are known to the State of California to cause cancer, birth defects or other reproductive harm.
for conduit or pipe routing.
b Do not locate holes in a panel that provides access to
key maintenance components such as filters and fan
assemblies.
c Do not locate where the conduit or piping blocks
airflow or obstructs hinged access doors.
2 Once a proper location is determined, drill a small pilot
hole completely through the panel. Then use a sharp hole
saw or a saber saw and cut from each side of the panel.
3 Seal the double-wall panel on each side with an
industrial/commercial grade silicone sealant or duct seal
compound. It is extremely important to seal each panel
hole or penetration securely so it is airtight, watertight,
and so that there is no exposed insulation.
WARNING
Flame and smoke can cause equipment
damage, severe personal injury, or death.
Before operating unit, seal all piping and
wiring holes on both inner and outer panels
with an industrial grade silicone sealant or
duct seal compound. Do not use a cutting
torch or expose panel to fire. Panel
damage can occur.
WARNING
La fumée et les flammes peuvent
endommager le matériel et causesr des
blessures graves ou la mort.
Avant d’utiliser le dispositif, obturer tous les
trous de passage de tubulures et de fils
ménagés dans les panneaux intérieurs et
extérieurs au moyen d’une pâte à base de
silicone ou d’un mastic d’étanchéite â
conduits de qualité industrielle.
Ne pas se servir d’un chalumeau coupeur ni
exposer les pannequx à une flamme nue
pour ne pas risquer de les endommager.
McQuay IM 777-6
Field Mounting Junction Boxes and
Other Components
For field mounting 4" × 4" or smaller junction boxes to the
standard panel exterior, use a minimum quantity of four, 3/16"
diameter pop rivets. Do not use self-tapping drill screws.
They will not tighten nor secure properly and panel
damage can occur.
If larger, heavier components require mounting on unit panels,
use through-bolts with flat washers through both outer and
inner panels. To maintain panel integrity, seal both ends with
an industrial/commercial grade silicone sealant or duct seal
compound.
The unit frame channel is another excellent location for
securing heavier components; self-tapping screws are not
acceptable. Ensure that the location permits the full operation
of all access doors and panels and does not interfere with other
vital components.
Duct Connections
Use flexible connectors on the outlet and inlet duct
connections of all units. Do not position down flow fans over
air ducts that are routed down into the building. Use a
discharge plenum when bottom connections are necessary
(Figure 15).
Figure 15: Discharge Plenum
D is c h a r g e
P le n u m
9
Mechanical Installation
If the unit has a top mixing box or economizer damper or a top
duct connection, field fabricate and install flashing to divert
moisture from the connection. The flashing must lap over the
standing seams of the top panels. The flashing also must lap
over the side edges of the unit (Figure 16).
Figure 18: Field-Installed Barrier Between Hoods
Figure 16: Flashing Over Top Panels and Sides of Units
In ta k e
F la s h in g
F la s h in g
D u c t
U n it to p
p a n e l
B a r r ie r
E x h a u s t
F la s h in g
F la s h in g
D u c t
Mounting Actuators
The installing contractor is responsible for the mounting of all
field-installed actuators. No provisions are made for the
location of these actuators due to the number of options and
arrangements available and the variety of specific applications.
Typically, actuators are mounted inside the cabinet. Provide
proper support for the actuator to avoid excessive stress in the
cabinet, linkage, or damper shafts.
Dampers and Hoods
Side dampers may be provided in the mixing box and
economizer sections of units. When dampers are provided, a
removable panel is located above the weather hood to provide
access to the damper drive shaft. Other access may be
available depending on the specific construction of the unit
(Figure 17).
Figure 17: Filler Panel Over the Weather Hood
Note: Damper blades are at full flow when open to 70 degrees.
Do not open blades further than 70 degrees.
Fresh air and return air dampers can be linked together and
driven from the same actuator if the dampers are the same size.
If the dampers are different sizes, they must be driven by
separate actuators and controlled appropriately. Exhaust
dampers are always driven by a separate actuator.
A typical rotary electric actuator can handle up to 40 sq. ft. of
damper. For pneumatic actuators, allow 5 in-lb per square foot
of damper area.
Remove screws
and panel to access
damper control shaft.
Hood
CAUTION
Maximum damper rotation is 70°. Maximum shaft torque is 205
inches/pound. Greater rotation or torque can cause equipment
damage.
ATTENTION
La rotation maximale des volets est de 70°. Le couple (torque)
maximum de l’arbre est de 205po/lb. Une plus grande rotation
(ou torque) peut endommager l’équipement.
When units are ordered with exhaust hoods and intake hoods
adjacent to each other, install a field-supplied barrier to
prevent recirculation of exhaust air into the intake openings.
(Figure 18).
10
McQuay IM 777-6
Mechanical Installation
Face and Bypass Section Mounting
Piping and Coils
Internal and external face and bypass sections are mounted
together using the instructions for horizontal components and
do not require additional instruction. Skyline air handlers are
provided with a bypass duct that is integral to the unit
construction and requires no field assembly.
When designing and installing piping:
Face and bypass dampers may or may not be linked together.
When dampers are placed before a single bank of coils, they
always are linked together and require a single actuator. When
dampers bypass a stacked or staggered coil, the dampers are
not linked and require multiple actuators.
• Follow applicable piping design, sizing, and installation
information in ASHRAE handbooks.
• Observe all local codes and industry standards.
• Do not apply undue stress at the connection to coil headers;
always use a backup pipe wrench.
• Support pipework independently of the coils.
Water Cooling Coils
Face and bypass dampers have a torque requirement of
10 in-lbs per square foot of damper face area.
Note: Use glycol in water coils for outdoor air handlers. Power
failures and other mechanical issues can expose coils to
freezing temperatures.
Piping Vestibules
• Water supply, water return, drain, and vent connections
extend through the end panel of the coil section. All
connections are labeled on the end panel.
For units that include a piping vestibule, cut the openings for
routing the field piping as required in the field. Carefully seal
passages cut through the panels to prevent air leakage. A
single metal thickness pan is provided in the bottom of the
curb-mounted vestibule. The pan can be removed if necessary.
If holes are cut into the pan for a piping passage, seal the holes
to prevent moisture leakage (Figure 19).
Figure 19: Seal Holes for Piping—Curb Mounted Units
• Water supply and water return connections are typically
male NPT iron pipe.
• When installing couplings, do not apply undue stress to the
connection extending through unit panel. Use a backup
pipe wrench to avoid breaking the weld between coil
connection and header.
• Follow recommendations of the control manufacturer
regarding types, sizing, and installation of controls.
Direct Expansion Coils
• The coil distributor and suction connection extend through
the end panel of the coil section.
• Check nozzle in distributor for proper tonnage.
• When a (field supplied) thermostatic expansion valve is
located outside the unit and connected directly to the
distributor (except on units with piping vestibules). Do not
apply heat to the body of the expansion valve.
Seal holes
cut for piping
For units with standard base rails, the vestibule is open to the
coil section; therefore, seal all holes to prevent air leakage.
Figure 20: Seal Holes for Piping—Standard Base Rail Units
• The thermostatic expansion valve must be the external
equalizer tube type. Connect the 1/4-inch diameter external
equalizer tube provided on the coil to the connection on the
expansion valve.
• Use care when piping the system, making sure all joints are
tight and all lines are dry and free of foreign material. For
typical refrigerant piping, see condensing unit product
manual.
Seal holes
cut for piping
McQuay IM 777-6
11
Mechanical Installation
Steam Coils
• Multiple coil installation—individually trap each coil or
group of coils.
Piping (see Figure 21)
• Steam supply and steam return connections typically are
male NPT iron pipe and are labeled on the end panel of coil
section. Connections extend through the coil section end
panel.
• Coils in series—use separate traps for each coil, or a bank of
coils.
• When installing couplings, do not apply undue stress to the
connection extending through unit panel. Use a backup
pipe wrench to avoid breaking the weld between coil
connection and header.
• Support piping independently of coils and provide adequate
piping flexibility. Stresses resulting from expansion of
closely coupled piping can cause serious damage.
• Do not reduce pipe size at the coil return connection. Carry
return connection size through the dirt pocket, making the
reduction at the branch leading to the trap.
• Coils in parallel—a single trap can be used, but an individual
trap for each coil is preferred.
• Do not attempt to lift condensate when using modulating or
on/off control.
• With coils arranged for series airflow, use a separate control
on each bank or coil in the direction of airflow.
Valves
• Do not use modulating steam valves on high pressure
systems.
• Properly size modulating valves. Do not undersize.
• Avoid freezing conditions (entering air temperatures below
35°F).
Coils
• Pitch all steam coils in units toward the return connection.
• McQuay strongly recommends 5JA, 8JA, 5RA and 8RA
coils.
• Do not drip supply mains through the coil.
• Supply 5 psi steam to coils at all times.
• Do not attempt to lift condensate when using modulating or
on/off control.
• Do not use modulating valves. Provide control by face and
bypass dampers.
• Install vacuum breakers on all applications to prevent
retaining condensate in the coil. Generally, connect the
vacuum breaker between the coil inlet and the return main.
The vacuum breaker should be open to the atmosphere and
the trap design should allow venting of large quantities of
air.
• Consider using two or three coils in series with two position
steam control valves on the coil or coils that handle 35°F or
colder air. Use a modulating valve on the downstream coil to
provide the desired degree of control.
Traps
Note: Do not place steam traps outdoors.
• Size traps in accordance with the manufacturers’
recommendations. Make sure the required pressure
differential is always available. Do not undersize.
• Use float and thermostatic or bucket traps for low pressure
steam. On high pressure steam, use bucket traps. Use
thermostatic traps only for air venting.
• Use bucket traps for on/off control only.
• Locate traps at least 12 inches below the coil return
connection.
12
• Thoroughly mix fresh air and return air before it enters the
coil. Also, to obtain true air mixture temperatures, properly
locate temperature control elements.
• As additional protection against freeze-up, install the trap
sufficiently below the coil to provide an adequate
hydrostatic head to remove condensate during an
interruption in the steam pressure. Estimate three feet for
each 1 psi of trap differential required.
• On startup, admit steam to coil ten minutes before admitting
outdoor air.
• Close fresh air dampers if steam supply pressure falls below
the minimum specified.
McQuay IM 777-6
Mechanical Installation
Figure 21: Piping Arrangements
Float and
thermostatic trap
Check Valve
Strainer
Control valve
modulating
two position
Gate Valve
High Pressure (over 25 psi)
Vacuum breaker
1/2" check valve
Steam main
Vacuum breaker
1/2" check valve
1/4" petcock
for continuous
air venting
Steam main
Return main
1"
min.
12" min.
1/4" petcock
for continuous
air venting
High pressure
float or bucket
trap
1" min.
12" min.
High pressure
bucket trap
Full size of
return conn.
Return main
5TA, 8TA, or 5HA coils. Condensate is lifted to overhead return
main
5GA or 8GA coils. Note that the
addition of a vacuum breaker to
permit the coil to drain during
shutdown.
Low Pressure (to 25 psi)
Steam main
Steam main
Vacuum breaker
1/2" check valve
Vacuum breaker
1/2" check valve
5J, 5G, 8J or 8G coils.
12" min.
Steam main
Return main
Vacuum breaker
1/2" check valve
5JA or 8JA coil. Installed in series.
Note that each coil must have a
separate control valve and trap.
12" min.
Return main
5RA, 8RA, or 5SA coils. Banked two
high, individual trapping of each coil as
shown is preferred.
Return main
Full size of
return conn.
5RA, 8RA, or 5SA coils. Installed
McQuay IM 777-6
13
Mechanical Installation
Water Heating Coils
Figure 22: Allow Adequate Distance Between Trap Outlet
and Drain Pan Outlet
CAUTION
Improper installation, use, or maintenance of water heating
coils can cause equipment damage. Read and follow
instructions carefully.
Pressure (P)
at the drain pan
2P
ATTENTION
Si l’installation, l’utilisation ou l’entretien des serpentins
de chauffage à eau sont inadéquats, ceci endommagera
l’équipement. Lire et suivre attentivement les instructions.
• Water supply and water return connections extend through
the end panel of the coil section. All connections are labeled
on the end panel.
• Water supply and water return connections are male NPT
iron pipe.
• When installing couplings, do not apply undue stress to the
connection extending through unit panel. Use a backup pipe
wrench to avoid breaking the weld between the coil
connection and header.
2P
Note: The door panels on some applications have a close
clearance over the drain pipes. Extend the drain fitting
with a coupling if necessary for door clearance
(Figure 23).
Note: Use material that can withstand freezing temperatures
for outdoor drain traps.
Note: Drain traps that dry out can allow cold air to seep into the
equipment.
Figure 23: Extend Drain Fitting for Door Clearance
• Follow recommendations of the control manufacturer
regarding types, sizes, and installation of controls.
• Do not use hot water coils with entering air below 40°F.
• If fresh air and return air are to be heated by a hot water coil,
carefully design the system to provide thorough mixing
before air enters the coil.
C le a r a n c e
• To prepare coils for winter operation, see Winterizing Water
Coils‚ page 30.
Drain Pan Traps
Run drain lines and traps full size from the drain pan
connection. Install drain pan trap to allow condensate to drain
freely. On both blow-through and draw-through units, the trap
depth and the distance between the trap outlet and the drain
pan outlet must be twice the static pressure in the drain pan
section under normal operation so the trap remains sealed
(Figure 22).
14
D r a in
McQuay IM 777-6
Mechanical Installation
Internal Isolation Assembly
Adjustment
Table 2: Motor Behind Fan Spring Mount Adjustments
On units with internally isolated fan and motor assemblies, the
assemblies are secured for shipment. with a tie-down at each
point of isolation.
Before Operating the Unit:
Remove the shipping brackets and tie-down bolts (see
Figure 25 and Figure 26) and discard. The shipping brackets
located on the opposite drive side of the unit are difficult to
access from the drive side of the unit. Either remove them
before the unit is assembled or remove the panel on the
opposite drive side to gain access.
The spring isolators under the four corners of the fan and
motor assembly are factory adjusted while the fan was not
running. See Table 1 and Table 2 below. With the unit
operating at normal cfm and static pressure, all the isolators
should be at the same height opening. If adjustments are
required, loosen the 1/2" cap screw on top of the isolator and
turn the adjusting bolt to lower or raise the fan and motor base.
Retighten the cap screw when adjustments are completed.
Table 1: Motor Beside Fan Spring Mount Adjustments
Spring mount adjustment at rest
Downblast
H
Spring mount adjustment at rest
Fan discharge
position
Top or bottom
horz. H
Downblast
H
Upblast
H
1
6.75
6.75
6.75
2
6.75
6.75
6.75
3
6.75
6.75
6.75
4
6.75
6.75
6.75
Unit sizes 003 – 035
Unit sizes 040 – 090
1
6.75
6.75
6.75
2
6.75
6.75
6.75
3
6.75
6.75
6.75
4
6.75
6.75
6.75
For models 040 through 090, the isolators should be at equal
For models 040 through 090, the isolators should be at equal
height during fan operation (6"). Center the fan outlet in the
outlet panel opening. If adjustment is required, loosen the cap
screw on top of the isolator assembly. Turn the adjustment nut
below the fan frame to lower or raise the fan motor and frame
assembly. Retighten the cap screw on top of the isolator
assembly.
Figure 24: Adjusting Large Spring Mount Assembly
Fan discharge
position
Top or bottom
horz. H
Upblast
H
1
3.75
3.75
4.25
2
4.25
3.75
4.25
3
4.25
3.75
4.25
4
3.75
3.75
4.25
1
6.00
6.75
6.75
2
6.50
6.75
6.75
3
6.50
6.75
6.75
4
6.00
6.75
6.75
Adjusting bolt
Unit sizes 003 – 035
6"
Unit sizes 040 – 090
McQuay IM 777-6
15
Mechanical Installation
Figure 25: Removing “Motor Behind” Shipping Brackets
Unit sizes 006 - 090
Figure 26: Removing “Motor Beside” Shipping Brackets
Unit sizes 006 - 090
S h ip p in g h o ld d o w n
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )
S h ip p in g b r a c k e t
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )
S e e d e ta il " A "
S p r in g h e ig h t
a d ju s tm e n t s c r e w
D im
"H "
P O S 2
P O S 3
M o to r
A ir flo w
F a n
P O S 1
P O S 4
F a n is o la to r p o s itio n n u m b e r s
S h ip p in g h o ld
d o w n s c re w
S p r in g h e ig h t
a d ju s tm e n t s c r e w
S h ip p in g
b ra c k e t
D e ta il A
16
McQuay IM 777-6
Electrical Installation
Electrical Installation
Wiring
Figure 27: Electrical Conduit Location
DANGER
Capacitor hazardous voltage! Failure to disconnect power
and discharge capacitors before servicing will result in serious
injury or death.
Disconnect all electric power (including remote disconnects)
before servicing. Perform lockout/tagout procedures to ensure
that power can not be energized. For variable frequency drives,
or other energy storing components that have been furnished
and mounted by either McQuay, or by others, refer to the
specific manufacturer’s literature for allowable waiting periods
for discharge of capacitors. Verify capacitors have been
discharged using an appropriate voltmeter.
Fan Motor
Junction Box
ADVERTISSEMENT
Voltage de condesateur à risquee de danger! À défaut de
débrancher la puissance électrique et de décharger le
condensateur avant de faire le service, il peut en résulter des
blessures sérieuses et même la mort.
Débranchez toute puissance électrique (incluant les
sectionneurs à distance) avant de faire du service. Assurezvous de procéder au cadenassage et à la pose d’avis assurant
que la puissance ne peut être rétablie.
Pour le variateur de fréquence variable ou tout autre
composante pouvant accumuler de l’énergie qui auraient été
fournis et installés par McQuay ou autres, se référer à la
littérature spécifique du manufacturier donnant les périodes
spécifiques d’attente nécessaires pour la décharge du
condensateur. Vérifier que le condensateur est totalement
déchargé avec les voltmètres appropriés.
CAUTION
Use copper conductors only. Failure to use copper
conductors can result in equipment damage.
ATTENTION
Utiliser du fil de cuivre seulement. La non utilisation de fil de
cuivre peut causer des dommages à l’équipement.
• Electrical service to the fan must correspond to the rated
voltage on the motor or electrical panel nameplate and
conform to the National Electric Code and local restrictions.
• Connect the fan section metal frame to the building
electrical ground.
• A door electrical interlock is not provided as standard.
• Thermal motor protection is external to the unit.
Locate electrical conduit entrances for units above the bottom
of the unit, high enough to clear components inside, but below
the bottom of the fan motor junction box (Figure 27).
McQuay IM 777-6
Conduit Entrance
(typical)
CAUTION
The base section of each cabinet has a drip pan installed
below every panel that drains to the outside frame trough. Any
holes cut through the bottom of the unit must also penetrate
the drip pan. If holes are cut in the drip pan, seal them to
prevent moisture leakage.
ATTENTION
Chaque cabinet est muni d’une base avec une panne
d’égouttement installée en-dessous de chaque panneau qui
évacuera l’eau vers la gouttière extérieure. Tous les trous
percés au bas de l’unité doivent pénétrer la panne
d’égouttement. S’il y a des trous dans la panne
d’égouttement, les sceller pour empêcher les fuites d’eau.
• When the unit is provided with an external junction box and
variable frequency drive (VFD), the VFD itself will be
mounted on the drive side fan panel inside the fan cabinet.
The external junction box will provide loose wire
connection to the VFD and to the motor. An external
mounted keypad/display control box will be provided and
connected to the VFD for manual adjustment of the VFD.
• When not being serviced, close and secure electrical panel
doors to prevent accidental contact with live parts and
prevent ingress of moisture and airborne contaminants.
• Control wiring—access to the VFD is through the fan
cabinet access door. Provide shielded cable only as
described in the VFD manual provided with the unit. Route
wire through panel so that it not interfere with any other
components or in the way of any access doors. Do not drill
through drip or drain pans. Refer to the VFD installation
manual provided with the unit for detailed control wiring
instructions.
17
Operation Guidelines
Operation Guidelines
Startup Checks
ATTENTION
When performing startup and service, always take thorough
safety precautions. Only trained, experienced personnel should
perform these functions.
WARNING
Rotating fan. Can cause severe injury or death. Before
servicing fans, lockout and tag out power.
AVERTISSEMENT
Ventilateur en rotation. Peut causer des blessures sévères
ou même la mort. Avant d’effectuer l’entretien des ventilateurs,
bloquer et couper la tension.
WARNING
Fire/electric shock hazard. Can cause property damage,
personal injury or death. Wire fan power supply and ground
motor frame in accordance with local electric codes.
Risques de dommages dans le moteur du ventilateur
électrique. Si Ia température de l’air a proximité du
ventilateurest élevée, le moteurdu ventilateur électrique peut
chauffer et brûler. Sur les transmetteurs d’air à circulation
transversale ou les transmetteurs dont le ventilateur est en
aval de l’unité de chauffage, régler la température de l’air
sortant de l’unité de chauffage à 40°C (104°F).
Before Starting the Unit:
Before entering fan section, make sure that fan electrical
power source is disconnected and locked in the OFF position.
1 Check that the unit is completely and properly installed
with ductwork connected.
2 Check that construction debris is removed/filters are
clean.
3 Check that all electrical work is complete and properly
AVERTISSEMENT
Risques d´incendie et d’électrocution pouvant causer des
dommages matériels, des blessures et même la mort.
L’alimentation électrique du moteur du ventilateur de même
que la mise à la terre du chàssis du moteur doivent être faits
conformément aux codes d’installations électriques en
vigueur.
WARNING
Fan motor requires overload protection. Failure to provide
motor overload protection can result in fire, property damage,
electric shock, personal injury, or death. Connect motor to an
overload protective device rated in compliance with local
electric codes.
AVERTISSEMENT
Risques d’incendie et d’électrocution pouvant causer des
dommages matériels, des blessures et même la mort.
Connecter au moteur du ventilateur électrique un dispositif de
protection contre les surcharges conforme aux codes
d’installations électriques en vigueur.
terminated.
4 Check that all electrical connections are tight and that the
proper voltage is connected. Phase imbalance must not
exceed 2%.
5 Check that ball bearings on the fan shaft and motor are
prelubricated and do not need grease before startup.
6 Check tightness of setscrews in bearings and fan
wheel(s). If retightening is needed, position the fan
wheel(s) per Table 3 or Table 4, page 19. Torque set
screws per Table 7, page 20.
CAUTION
Equipment damage due to loose fasteners represents
improper start-up and equipment abuse. It is not covered by
the warranty.
ADVERTISSEMENT
Les dommages dus à des attaches installées de façon
inappropriée représentent un démarrage inadéquat et un
abus d’équipement. Ceci n’est pas couvert par la garantie.
CAUTION
Do not overheat fan motor. High air temperatures in the fan
section can cause the fan motor to burnout. On draw-through
air handlers or air handlers with the fan section down the air
stream from the heating section, the discharge air temperature
of the heating section must not exceed 104°F (40°C).
1 Check alignment of fan and motor sheaves and belt tension.
Adjust if necessary. Check tightness of sheave setscrews
and/or capscrews. See Table 7, page 20.
2 Leak test the thermal system to verify that connections are
tight.
3 Check that the condensate drain is trapped.
4 Rotate the shaft by hand to be sure it is free.
Fan Startup:
Start and run fan. Observe the rotation. If the fan operates
backward, reverse two legs of the three-phase motor
connections.
18
McQuay IM 777-6
Operation Guidelines
Note: Variable pitch fan drives usually are provided for
operation in the mid-speed adjustment range. However,
the drives usually ship with the adjustment opened up for
minimum fan speed. Adjust the drives for the proper
airflow. See Fan Drive‚ page 24.
After the First 48 Hours of Operation:
Table 4: Wheel-to-Inlet Funnel Relationship—Forward
Curved Type Fan Wheels
Forward curved
Unit sizes 003 to 035
Diameter (in)
Unit sizes 040 to 090
C (in) C (mm)
1 Disconnect and lock electrical power source.
9x4
0.25
6.35
2 Check tightness of all bearing, wheel, and sheave setscrews
9x7
0.13
3.30
(or capscrews). See Table 7, page 20.
B
A
E q u a l s p a c in g
a ll a r o u n d
0.24
6.10
22.38 (Class 1 & 2) 0.41
20 (Class 1 & 2)
10.41
0.25
6.35
10
0.22
5.59
12
0.35
8.89
30 (Class 1 & 2)
0.47
11.94
15
0.44
11.18
33 (Class 1 & 2)
0.50
12.70
18
0.25
6.35
36 (Class 1 & 2)
0.75
19.05
20 (Class 1 & 2)
0.73
8.54
22 1/2 (Class 1 & 2) 0.59
14.99
24 1/2 (Class 1 & 2) 0.56
14.22
tensioned sufficiently to slip one to two seconds at startup
perform satisfactorily, extending life and reducing vibration. If
retensioning is necessary, be certain to retain sheave
alignment.
Figure 28: Wheel-to-Inlet Tunnel Relationship—Airfoil Type
Fan Wheels (Housed)
C (in) C (mm)
9x9
3 Recheck belt tension and adjust if necessary. Belts that are
Fan Wheel Alignment
Diameter (in)
Note:
0.47
11.94
27.62 (Class 1 & 2) 0.47
25 (Class 1 & 2)
11.94
1. To obtain rated air performance, dimensional relationship must be
held.
2. Adjust dimension C by loosening wheel hub setscrews, shifting
wheel(s) axially as needed, and retightening setscrews
Figure 30: Wheel-to-Inlet Funnel Relationship—13 to 36
Plenum Fans
A
Cross Section Reference
EQUALLY SPACED
AROUND DIAMETER
Table 3: Wheel-to-Inlet Funnel Relationship—Airfoil Type
Airfoil
B
Unit sizes 003 to 035
A
(mm)
B
(in)
B
(mm)
A
(mm)
A
(in)
B
(mm)
13.22 4.56
116
0.21
5.33 20.00 7.19
183
0.31
7.87
14.56 5.06
129
0.21
5.33 22.25 7.69
195
0.33
8.38
16.18 5.62
17.69 6.90
143
0.21
5.33 24.50 8.56
217
0.31
7.87
175
0.22
5.59 27.00 9.47
241
0.63 16.00
21.56 7.59
193
0.24
6.10 30.00 10.47
266
0.39
9.91
24.00 8.45
215
0.23
5.84 33.00 11.75
298
0.38
9.65
36.50 12.78
325
0.38
9.65
40.25 14.31
363
0.50 12.70
Dia.
Note:
A
(in)
Unit sizes 040 to 090
Dia.
A
(in)
1. To obtain rated air performance, dimensional relationship must be
held.
2. To obtain dimension A, loosen setscrews in wheel hub(s), shifting
wheel(s) axially as needed, and retightening setscrews.
3. To obtain dimension B, loosen screw and washer fasteners around
periphery of funnel(s), shifting funnel radially as required, and retorquing fasteners.
Figure 29: Wheel-to-Inlet Funnel Relationship—Forward
Curved Type Fan Wheels
C
In le t
F u n n e l
McQuay IM 777-6
W h e e l
C
In le t
F u n n e l
FROM FUNNEL END TO
FANWHEEL OPENING END
A
C
Table 5: Wheel-to-Inlet Funnel Relationship—13 to 36
Plenum Fan
Wheel-Funnel Parameters
Size
A
B
C
13
0.25
0.91
3.50
15
0.25
0.91
3.50
16
0.25
0.91
3.50
18
0.38
0.86
3.88
20
0.42
1.11
3.88
22
0.45
1.11
3.88
24
0.51
1.11
3.88
27
0.55
1.36
4.50
30
0.62
1.36
4.50
33
0.55
1.50
5.00
36
0.63
1.50
5.00
19
Operation Guidelines
Figure 31: Wheel-to-Inlet Funnel Relationship—40 to 60
Plenum Fans
Cross Section Reference
A
FUNNEL END TO FAN
WHEEL OPENING
EQUALLY
SPACED AROUND
DIAMETER
B
27
3/8
19.2
22
30
1/2
41.7
55
33
1/2
41.7
55
36
1/2
41.7
55
40
1/2
41.7
55
44
1/2
41.7
55
49
1/2
41.7
55
54
1/2
41.7
55
60
3/4
115
150
Figure 32: Wheel-to-Inlet Funnel Relationship—Inline Fans
Overlap
C
Table 8: Wheel-to-Inlet Funnel Relationship—Inline Fans
Wheel—funnel overlap
Table 6: Wheel-to-Inlet Funnel Relationship—40 to 60
Plenum Fan
Wheel-Funnel Parameters
Size
A
B
C
40
0.82
2.00
4.88
44
0.91
2.25
5.50
49
1.00
2.50
5.50
54
1.10
2.50
5.50
60
1.23
3.00
5.50
Setscrews on MPQ fan wheels must be installed using a
calibrated torque wrench to the value listed below, ±5%.The
fasteners must be periodically checked to satisfy agency
requirements for components on rotating machinery.
Table 7: Setscrew Torque Specifications—Belt Drive
Plenum Fans Only
Size
Overlap
150
.375
165
.438
182
.562
200
.625
222
.688
245
.750
270
.812
300
.875
330
1.000
365
1.125
402
1.250
445
1.375
Table 9: Bearing Collar and Wheel Hub Set Screw Torque
(All Fans Except Belt Drive Plenum Fans)
Torque (ft.-lb)
Fan Size
Aluminum
Steel
Set screw
Diameter (in)
Minimum torque
ft/lbs
kg/m.
13
3/8
19.2
N/A
15
3/8
19.2
N/A
1/4
5.5
.76
1/16
10.5
1.45
16
3/8
19.2
N/A
18
3/8
19.2
N/A
3/8
19.0
2.63
29.0
4.01
20
3/8
19.2
N/A
7/16
22
3/8
19.2
N/A
1/2
42.0
5.81
N/A
5/8
92.0
12.72
24
20
Setscrew Size
3/8
19.2
McQuay IM 777-6
Operation Guidelines
Operating Limits
Do not exceed the operating limits in Table 10. A fan wheel
operated beyond the rpm and temperature limits shown can
suffer permanent distortion or fracture. The resulting
unbalance can cause severe unit vibration.
Table 10: Unit Sizes 003 to 035
Fan operating limits
Forward curved—housed
Diameter
9×4
9×7
9×9
10.62
12.62
15
18
20
22.25
Maximum rpm Class I
N/A
2189
2223
1934
1614
1328
1155
1050
944
24.50
858
Maximum rpm Class Il
2700
2854
2896
2518
2091
1725
1450
1200
1030
910
Diameter
13.22
14.56
16.19
19.69
21.56
24.00
Maximum rpm Class I
3000
3000
2300
2000
1700
1500
Maximum rpm Class Il
4335
3918
3457
2858
2427
2255
Airfoil—housed
Figure 34: Torque for AF Variable Inlet Vanes (in–lb)
150
6
.5
14
AF
750
800
850
900
1000
Fan speed (rpm)
22
3.
1
AF
100
90
80
70
60
50
40
35
30
1500
450
500
550
600
650
700
750
800
850
900
1000
400
350
250
100
90
80
300
150
19
6.
1
AF
4500
00
0.
2
FC
69
9.
1
AF
4000
FC
56
1.
2
AF
3500
.
22
A
3000
38
0
.0
4
F2
1500
200
200
Torque (in–lb)
250
Torque (in–lb)
FC
FC 36.
0
FC 33. 0
00
3
0.
FC
25
27
.
62
FC
25
.0
0
400
350
300
450
400
350
300
250
200
2500
500
2000
Figure 33: Torque for FC Variable Inlet Vanes (in–lb)
Fan speed (rpm)
Table 11: Unit Sizes 040 to 090
Fan operating limits
Forward curved—housed
Diameter
20
22.38
25
27.62
30.25
33
36
Maximum rpm Class I
1010
930
790
690
650
600
560
Maximum rpm Class Il
1281
1178
1011
910
835
763
715
Airfoil—housed
Diameter
20
22.25
24.5
27
30
33
36.5
Maximum rpm Class I
2077
1875
1691
1479
1328
1209
1073
Maximum rpm Class Il
2703
2413
2199
1928
1730
1579
1401
Figure 35: Torque for FC Variable Inlet Vanes (in–lb)
Figure 36: Torque for AF Variable Inlet Vanes (in–lb)
2000
300
2
FC
200
Torque (in–lb)
5
4.
5
2
2.
2
FC
1500
0
.0
0
C2
F
00
.
18
150
FC
00
.
15
FC
100
90
80
70
60
62
2.
1
FC
Torque (in–lb)
0
250
25
0.
4
AF
1000
900
800
700
600
500
400
350
300
250
200
50
8.
3
AF
A
0
.0
3
F3
00
0.
3
AF
00
0
.5
24 2.25
F
A F2
00
0.
A
2
AF
7.
2
AF
150
50
Fan speed (rpm)
McQuay IM 777-6
3000
2500
2000
1500
550
600
650
700
750
800
850
900
1000
2000
1500
500
550
600
650
700
750
800
850
900
1000
450
400
350
100
Fan speed (rpm)
21
Operation Guidelines
Table 12: Operating Limits—Plenum Fans
Fan operating limits
Plenum fans
Diameter
Class
Maximum rpm
13.5
15
16.5
18.25
20
22.25
24.5
27
30
33
36.5
2
2
2
2
2
2
2
2
2
2
2
40.25 44.50
2
2
49
54.25
60
2
2
2
986
891
75
75
3,909 3,468 2,820 2,930 2,674 2,403 2,183 1,860 1,783 1,620 1,465 1,329 1,202 1,091
Maximum motor HP
7.5
10
15
15
15
20
25
30
40
40
50
60
75
75
Table 13: Operating Limits—Inline Fans, Twin Fans
Fan operating limits
Inline fans
Diameter
18.25
20
22.25
24.5
27
30
33
36.5
40.25
44.50
49
54.25
Maximum rpm Class I
2727
2488
2236
2041
1835
1665
1476
1330
1208
1072
973
880
Maximum rpm Class II
3409
3111
2796
2551
2294
2082
1846
1662
1510
1340
1216
1100
Diameter
9x9
10.62
12.62
15
18.12
20
Maximum rpm
2575
2400
2000
1700
1400
1200
Maximum HP
10
15
15
30
40
40
Twin fans
Fan Vibration Levels
Figure 37: Torque Requirements at 100% WOV for
SWSI Plenum Fans with NESTED Inlet Vane
5000
60
0
Each unit as shipped is trim balanced to operate smoothly. To
provide satisfactory operation after shipping and installation,
use the accepted industry guidelines for field balancing fans.
See Table 14.
54
2
4000
49
0
3000
Table 14: Vibration Levels
44
5
Note:
1000
900
800
700
40
2
36
5
Fan speed (rpm)
Vibration
800 or less
5 mils maximum displacement
801 or greater
0.20 in/sec. maximum velocity
Excessive vibration from any cause contributes to premature fan and
motor bearing failure. Monitor overall vibration levels every six
months of operation. An increase in levels is an indication of potential
trouble.
600
Vibration Causes
500
1 Wheel imbalance.
33
0
Torque
(in-lb
)
Torque
(lb./in.)
2000
a Dirt or debris on wheel blades.
300
400
b Loose set screws in wheel hub or bearing-to-shaft.
270
300
c Wheel distorted from overspeed.
2 Bent shaft.
245
200
3 Drive faulty.
a Variable pitch sheaves—Axial and radial runout of
Fan Speed (rpm)
3000
2000
1500
700
800
900
1000
600
500
400
300
200
100
flanges; uneven groove spacing; out of balance. Also
similar faults in driven sheave.
b Bad V-belts; lumpy, or mismatched; belt tension too
tight or too loose.
4 Bad bearings, loose bearing hold-down bolts
5 Motor imbalance
6 Fan section not supported evenly on foundation
22
McQuay IM 777-6
Service and Maintenance
Service and Maintenance
Periodic Maintenance
1 Check all moving parts for wear every six months.
2 Check bearing collar, sheave, and wheel hub setscrews,
Compatibility of grease is critical. Relubricatable bearings are
supplied with grease fittings or zerks for ease of lubrication
with hand or automatic grease guns. Always wipe the fitting
and grease nozzle clean.
sheave capscrews, and bearing hold-down bolts for
tightness every six months.
3 Annually check and snug all electrical connections.
Inspect for signs of water damage such as corrosion and
repair if necessary. Check ground conductor and
connection integrity. Service if needed.
Ball Bearing Lubrication
CAUTION
Bearing overheating potential. Can damage the equipment.
Do not overlubricate bearings. Use only a high grade mineral
grease with a 200°F safe operating temperature. See below for
specific recommended lubricants.
Motor Bearings
Supply and return fans—Supply and return fan motors
should have grease added after every 2000 hours of operation.
Using the following procedure, relubricate the bearings while
the motor is warm, but not running. Use one of the greases
shown in Table 15.
Table 15: Recommended Lubricants and Amounts for Fan
Motor Bearings
Mfr. Grease
NEMA Size
Amount to Add
(oz.)
Texaco, Polystar
or
Polyrex EM (Exxon Mobile)
or
Rykon Premium #2
or
Penzoil Pen 2 Lube
56 to 140
140
180
210
250
280
320
360
400
440
0.08
0.15
0.19
0.30
0.47
0.61
0.76
0.81
1.25
2.12
1 Remove and clean upper and lower grease plugs.
CAUTION
For safety, stop rotating equipment. Add one half of the
recommended amount shown in Figure 18. Start bearing,
and run for a few minutes. Stop bearing and add the second
half of the recommended amount. A temperature rise,
sometimes 30°F (1°C), after relubrication is normal. Bearing
should operate at temperature less than 200°F (94°C) and
should not exceed 225°F (107°C) for intermittent operation.
For a relubrication schedule, see Table 16. For applications
that are not in the ranges of the table, contact McQuay.
CAUTION
The tables below state general lubrication
recommendations based on our experience and are
intended as suggested or starting points only. For best
results, specific applications should be monitored regularly
and lubrication intervals and amounts adjusted accordingly.
Table 16: Relubrication Intervals
(Use NLGI #2 Lithium or Lithium Complex Grease)
Speed
Temperature
Cleanliness
Relub. intervals
Up to 120°F
100 rpm
Clean
6 to 12 months
(50°C)
Up to 150°F
500 rpm
Clean
2 to 6 months
(65°C)
Up to 210°F
2 weeks to 2
1000 rpm
Clean
months
(100°C)
Over 210°F
1500 rpm
Clean
Weekly
(100°C) to
250°F (120°C)
Up to 150°F
Above 1500 rpm
Dirty/wet
1 week to 1 month
(65°C)
Over 150°F
Max catalog rating (65°C) to 250°F
Dirty/wet
Daily to 2 weeks
(120°C)
Above 250°F
Contact Browning
(120°C)
Table 17: Recommended Lubricants for Fan Shaft Ball
Bearings
Name
Temperature
Base
Thickener
NLGI
grade
Texaco,
Premium RB
Mobile, AW2
30° to 350°F
(34° to 177°C)
40° to 437°F
(40° to 175°C)
68° to 356°F
(50° to 180°C)
60° to 450°F
(51° to 232°C)
Parafinic
mineral oil
Mineral oil
Lithium
2
Lithium
2
Synthetic
Lithium
2
Synthetic
Lithium
2
40° to 300°F
(40° to 149°C)
Mineral oil
Lithium
2
2 Insert a grease fitting into the upper hole and add clean
grease (Table 15) with a low pressure gun.
3 Run the motor for five minutes before replacing the
plugs.
Note: Specific greasing instructions are located on a tag
attached to the motor. If special lubrication instructions
are on the motor, they supersede all other instructions.
Fan Shaft Bearings
Any good quality lithium or lithium complex base grease,
using mineral oil, conforming to NLGI grade 2 consistency,
and an oil viscosity of 455-1135 SUS at 100°F (100-200 cSt at
40°C) may be used for relubrication.
McQuay IM 777-6
Mobile, SHC
100
Chevron,
Altiplex
Synthetic
Exxon, ronex
MP
Note:
Temperature ranges over 225°F are shown for lubricants only. High
temperature applications are not suitable for standard air handler
components.
23
Service and Maintenance
VM and VP Variable Pitch Key Type Sheaves
Table 18: Recommended Fan Relubrication Grease Charge
Shaft Size (in)
1/2 to 3/4
7/8 to 1-3/16
1-1/4 to 1-1/2
1-11/16 to 1-15/16
2 to 2-7/16
2-1/2 to 2-15/16
3 to 3-7/16
3-1/2 to 4
OZ.
0.03
0.10
0.15
0.20
0.30
0.50
0.85
1.50
Shaft Size
20 mm
25-30 mm
35-40 mm
45-50 mm
55-60 mm
65-70 mm
75-80 mm
85-105 mm
Grams
0.85
2.84
4.25
5.67
8.51
15.59
24.10
42.53
Fan Drive
WARNING
Before servicing fans, lock out and tag out all power to the
unit. Fans or belts can cause severe personal injury or death.
AVERTISSEMENT
Avant de faire le service sur les ventilateurs,couper et
indiquer que le courant est coupé. Les ventilateurs ou les
courroies peuvent causer des blessures personnelles graves
ou entraîner la mort.
WARNING
Do not open the hinged access door and screw-fastened
access panels while the unit is operating. Moving parts and
strong suction forces can cause severe personal injury or
death.
AVERTISSEMENT
Ne pas ouvrir les portes d’accès à charnières et les
panneaux à vis lorsque l’unité fonctionne. Les pièces
mobiles et le niveau de succion peuvent causer des blessures
personnelles graves ou même entraîner la mort.
Upon completion of the air balance, replace the variable
pitched motor sheave with a properly sized, fixed sheave. A
matching fixed sheave provides longer belt and bearing life
and minimizes vibration. Initially, it is best to have a variable
pitched motor sheave for the purpose of air balancing. Once
the balance is achieved, fixed sheaves maintain balancing and
alignment more effectively. Replace the adjustable sheaves
with fixed sheaves.
With the electrical power disconnected, locked and tagged out,
measure the diameter of the V-belt outer surface where it
passes around the sheave (pitch diameter). Calculate fan speed
from the motor nameplate rpm.
Fan rpm = motor rpm ×
Mounting
1 Mount all sheaves on the motor or driving shaft with the
setscrews A toward the motor.
2 Verify that 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 To adjust sheave pitch diameter for desired speed, open
moving parts by half or full turns from closed position.
Do not open more than five full turns for A belts or
six full turns for B belts.
3 Replace external key E and securely tighten setscrews B
over key and setscrews C into keyway in fixed half of the
sheave.
4 Put on belts and adjust belt tension. Do not force belts
over grooves. See Fan Drive Belt Adjustment‚ page 28.
5 Make future adjustments 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.
6 To provide the same pitch diameter, adjust both halves of
the two-groove sheaves by the same number of turns
from closed position.
7 Verify that all keys are in place and that all se screws are
tight before starting drive. Check setscrews and belt
tension after 24 hours service.
Figure 38: VP Type Sheave Adjustment
A
B
E
Single Groove
D
C
Key E projects
to provide a grip
for removal.
Measured diameter at motor sheave
B
Do not operate
sheeves with flange
projecting beyond
the hub end.
B
Measured diameter at fan sheave
A
E
Two Groove
D
C
24
C
McQuay IM 777-6
Service and Maintenance
LVP Variable Speed Sheaves
9 Put on belts and adjust belt tension. Do not force belts
over grooves. See Fan Drive Belt Adjustment‚ page 28.
Mounting
1 Slide sheave on motor shaft so that the side of the sheave
with setscrew A is next to the motor when setscrew A is
in the hub or barrel of the sheave.
10 Before starting the drive, ensure that all keys are in place
and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of service.
2 When setscrew A is at an angle in the center flange B,
Adjusting
1 Slack off belt tension if belts have been installed.
mount it away from the motor so that the outer locking
ring and flange can be removed to get to the setscrew.
2 Loosen setscrews D.
3 To remove the flange and locking ring:
a Loosen setscrews D.
3 Loosen but do not remove capscrews E.
b Loosen but do not remove capscrews E.
4 Remove key F.
c Remove key F.
Note: This key projects a small amount to provide a grip for
removing.
Note: This key projects a small amount to provide a grip for
removing.
5 Adjust pitch diameter by opening or closing the movable
flanges by half or full turns.
d Rotate the flange counterclockwise until it disengages
Note: Two-groove sheaves are supplied with both grooves
set at the same pitch diameter.
the threads on the sheave barrel.
4 Verify that the driving and driven sheaves are in
6 To provide the same pitch diameter for satisfactory
alignment and the shafts are parallel. When aligning twogroove sheaves, allow room between the sheave and
motor to access capscrews E.
operation, move both movable flanges the same number
of turns. Do not open sheaves more than five turns for A
belts or six turns for B belts.
5 Insert key C between the sheave and the shaft and tighten
setscrew A securely.
7 Replace key F.
8 Tighten setscrews D and capscrews E.
6 If flange and locking ring have been removed, when
9 If belts have been installed, readjust belt tension. If belts
replacing them make sure that the inner and outer flanges
are open from the closed position by the same amount as
the other flange. Determine this by accurately measuring
the top width of the grooves.
have not been installed, install them and adjust belt
tension. Do not force belts over grooves. See Fan Drive
Belt Adjustment‚ page 28.
10 Before starting the drive, ensure that all keys are in place
7 Insert key F.
and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of operation.
8 Tighten setscrews D and capscrews E.
Figure 39: LVP Type Sheave Adjustment
A
A
A
E
E
E
C
C
F
A
F
D
D
D
B
Section A-A
McQuay IM 777-6
Section A-A
25
Service and Maintenance
MVP Variable Speed Sheaves
4 Any pitch diameter can be obtained within the sheave
Mounting
1 Verify both driving and driven sheaves are in alignment
and the shafts are parallel. The centerline of the driving
sheave must be in line with the centerline of the driven
sheave. See Figure 40.
2 Verify that all setscrews are torqued to the values shown
in Table 19 before starting drive. Check setscrew torque
and belt tension after 24 hours of service.
Adjusting
1 Adjust motor base forward to release belt tension.
Remove the belts for easier adjustment.
2 Loosen, but do not remove both of the locking setscrews
A in the outer locking ring by using a hex key or torque
wrench with a hex bit.
3 Adjust sheave to desired pitch diameter by turning the
outer locking ring. Use a spanner wrench or drift inserted
into the three holes that are located 120° apart on the
ring.
range. One complete turn of the outer locking ring
changes the pitch diameter 0.233".
5 Do not open sheaves more than the following:
a Do not open B sheaves more than 4 3/4 turns for the A
belts or 6 turns for the B belts.
b Do not open C sheaves more than 9 1/2 turns.
c Do not open 5V sheaves more than 6 turns.
d Do not open 8V sheaves more than 8 turns.
6 Tighten BOTH locking screws A in the outer locking
ring before operating the drive. Use a torque wrench and
tighten to the value shown in Table 19.
7 Replace belts and adjust the motor base to tension the
belts properly. See Fan Drive Belt Adjustment‚ page 28.
8 Do not loosen any screws other than the two locking
screws A in the outer locking ring when adjusting the
sheave pitch. Do not operate the drive until the locking
screws have been set to the torque specifications.
Table 19: Screw Torque Values
Socket head cap screws
Nominal screw size
(dia–-thds/in)
26
Seating torque
Flat head socket
screws
Hollow head set screws only
Lengths equal or greater than dia.
For lengths (L)) less than dia.
Seating torque
Seating torque
Seating torque
Length (L)
Seating torque
(in–lbs)
(in–lbs)
(in–lbs)
(in–lbs)
(in–lbs)
(in–lbs)
(in–lbs)
1/4–20NC
150
12.5
100
87
7.3
3/16
50
5/16–11NC
305
25.4
200
165
13.8
1/4
90
150, 250
3/8–16NC
545
45.4
350
290
24.2
1/4, 5/16
1/2–13NC
1300
108.3
N/A
620
51.7
N/A
N/A
5/8–11NC
N/A
N/A
N/A
1225
102.1
N/A
N/A
McQuay IM 777-6
Service and Maintenance
Figure 40: Sheave Adjustment
Must be
parallel
Bearing
Center lines
must coincide
Motor
Adjustable
Sheave
Must be
parallel
Figure 41: Sheave Adjustment
A d ju s ta b le
C e n te r - F la n g e
F ix e d
C e n te r - F la n g e
( 2 ) L o c k in g
S e ts c re w s "A "
F la th e a d S o c k e t S c r e w s
(D o N o t R e m o v e )
S p lit T a p e r
B u s h in g
C a p s c re w s
(D o N o t R e m o v e )
McQuay IM 777-6
S ta tio n a r y
E n d - F la n g e
O u te r
L o c k in g - R in g
In n e r L o c k in g - R in g
( 3 ) H o le s fo r
S p a n n e r W re n c h
o r D r ift
27
Service and Maintenance
Fan Drive Belt Adjustment
WARNING
General Rules of Tensioning
1 The ideal tension is the lowest tension at which the belt
does not slip under peak load conditions.
Moving belt and fan can cause severe personal injury or death.
During installation and filter maintenance:
• Verify that the belt and fan guards on plenum fan units are
2 Check tension frequently during the first 24 to 48 hours of
always in place.
operation.
• Lock and tag out fans to prevent accidental start up.
3 Over tensioning shortens belt and bearing life.
• Do not enter the filter compartment until the fan is
4 Keep belts free from foreign material that can cause
completely stopped.
slippage.
• Use approved equipment for reaching filters located above
5 Inspect V-drive on a periodic basis. Adjust tension if the
normal reach. Do not step on filter frames or unit
components.
belt is slipping. Do not apply belt dressing. This can
damage the belt and cause early failure.
• Floor surfaces must be dry and free of oil or grease.
Tension Measurement Procedure
1 Measure the belt span. See Figure 42.
WARNING
Pendant l’installation et où l’entretien des filtres, une courroie
en mouvement ou un ventilateur en opération peuvent causer
des blessures graves où même causer la mort.
2 Place belt tension checker squarely on one belt at the center
of the belt span. Apply force to the checker, perpendicular
to the belt span, until the belt deflection equals belt span
distance divided by 64. Determine the force applied while
in this position.
• S’assurer que les gardes de courroie et de ventilateur sont
toujours en place.
• Verouiller les démarreurs des ventilateurs et afficher un avis
3 Compare this force to the values in Table 20.
de mise-en-garde afin de prévenir tout accident ou
démarrage.
Figure 42: Drive Belt Adjustment
Deflection =
• Attendre que le ventilateur soit complètement arrêté avant
Belt span
64
d’entrer dans l’unité.
• Utiliser seulement des équipements approuvé pour joindre
les bancs de filtres; ne pas mettre soit sur les cadres des
filtres ou même sur toutes composantes de l’unité.
Belt span
• La surface des planchers doit être sec et libre de toute trace
d'huile et où de graisse.
Table 20: Belt Deflection Force (per Browning Specifications)
Number of belts (deflection force lbs)
Cross
section
Small sheave
diameter (in)
0.0 to 3.5
A, AX
B, BX
5V, 5VX
28
1
2
3+
min
max
min
max
min
max
3.0
5.0
2.5
4.0
2.0
3.5
3.6 to 4.4
3.5
5.0
3.0
4.5
2.0
4.0
4.5 +
4.0
5.5
3.0
5.0
2.5
4.5
0.0 to 5.4
5.5
8.0
4.5
7.0
3.5
5.5
5.5 to 7.6
5.5
8.5
4.5
7.5
3.5
5.5
7.7 +
6.5
9.0
5.0
8.0
4.0
6.5
0.0 to 8.5
7.0
11.0
5.5
9.0
4.0
7.0
8.6 TO 12.0
8.5
13.0
6.5
10.5
5.0
8.0
12.1 +
10.0
15.0
7.5
11.5
5.5
9.0
McQuay IM 777-6
Service and Maintenance
Front Load Filter Option
Table 21: Filter Pressure Drops
Front loaded filter options require that the filters be removed
and replaced from inside the unit.
To remove filters, rotate the wire clips. This releases both the
prefilter and the final filter. When installing clean filters, check
to verify the filters are fully seated in the frame (Figure 43).
Figure 43: Frame and Filters with Holding Clips
Bag filters—DriPak 2000
Efficiency
45%
65%
85%
95%
Rated velocity (fpm)
625
500
500
500
Initial pressure drop
Initial pressure drop
.20–.26 .21–30 .34–.48
1.0
1.0
1.0
.50–.70
1.0
Cartridge filters—Varicel II MH, 4.25" deep
Efficiency
65%
85%
95%
Efficiency
Rated velocity (fpm)
500
500
500
Rated velocity (fpm)
Initial pressure drop
.43
.61
.70
Initial pressure drop
Final pressure drop
1.5
1.5
1.5
Final pressure drop
Cartridge filters—Varicel SH, 12" deep
Efficiency
70%
Rated velocity (fpm)
500
Initial pressure drop
.39
Final pressure drop
1.2
Pleated panel filters
Type
F in a l
F ilte r
P r e filte r
F ilte r
F ra m e
R o ta te
W ir e C lip s
Perfect pleat
AMAir 300 4"
Efficiency
30%
30%
Rated Velocity (fpm)
500
625
Initial Pressure Drop
.36
.36
Final Pressure Drop
1.0
1.0
5700 filters
Filter Gauges
Efficiency
N/A
Rated velocity (fpm)
500
Filter gauges indicate pressure drop for installed filters. If
prefilters are present, the gauge will indicate the pressure drop
for both pre- and final filters
Initial pressure drop
.25
Final pressure drop
1.0
Table 21 shows the typical filter pressure drop for clean filters
at rated air flow. The tables also show a final pressure drop for
front loaded filters.
Size
Where a single filter gauge is used, the prefilters can be
removed to check the pressure drop of the final filters.
Figure 44: Filter Gauge
Coils
Pleated 62 Plus filters
2"
4"
70%
70%
Initial pressure drop
.42
.37
Final pressure drop
1.0
1.0
Efficiency
1 The coil must be clean to obtain maximum performance.
Check once a year under normal operating conditions
and, if dirty, brush or vacuum clean. Use a chemical coil
cleaner on multiple row coils. Read and follow the
chemical cleaner’s instructions as some cleaners may
contain harsh chemicals. Take care not to damage fins
while cleaning.
2 Drain pans in any air conditioning unit may have some
moisture. Algae, etc., can grow due to airborne spores
and bacteria. Periodic cleaning is necessary to prevent
this buildup from plugging the drain and causing the
drain pan to overflow. Also, keep the drain pans clean to
prevent the spread of disease. Cleaning should be
performed by qualified personnel.
McQuay IM 777-6
29
Service and Maintenance
3 Dirt and lint can clog the condensate drain, especially
with dirty filters. Inspect twice a year to help avoid
overflow.
Winterizing Water Coils
Coils can freeze due to air stratification or failure of outdoor
air dampers and/or preheat controls. Do not depend on routine
draining of water cooling coils for winter shutdown as
insurance against freeze-up. Severe coil damage can result.
Drain all coils as thoroughly as possible and then treat in the
following manner.
• Fill each coil independently with an antifreeze solution
using a small circulating pump and again thoroughly drain.
• Check freezing point of antifreeze before proceeding to next
coil. Due to a small amount of water always remaining in
each coil, there is a diluting effect. The small amount of
antifreeze solution remaining in the coil must always be
concentrated enough to prevent freeze-up.
Note: Carefully read instructions for mixing antifreeze solution
used. Some products have a higher freezing point in
their natural state when mixed with water. McQuay
International is not responsible for the freezing of
coils.
WARNING
Mold can cause personal injury. Clean drain pan regularly so
mold does not develop.
AVERTISSEMENT
La moisissure présente un danger respiratoire. Pour éviter
la moisissure, nettoyer régulièrement le bassin de drainage.
If fan replacement is required, the entire fan assembly can be
pulled out the side of the cabinet. The fan assembly includes
the fan housing, the bearing support, and the fan base.
Removing the Fan Assembly
1 Remove the side panels and any intermediate supports
(follow instructions for side panel removal).
2 Once the panels and any intermediate supports are
removed, disconnect the neoprene bulk head seal that is
attached to the fan discharge.
3 Remove the four discharge angles that hold the neoprene
canvas in place around the discharge opening.
4 Disconnect the fan sled from each of the corner mounts
and pull the entire assembly out the side of the unit.
5 After the fan sled is out, loosen the fan bearings and pull
out the shaft.
6 Disconnect the fan housing from the fan sled, and
bearing support by removing the attaching bolts.
7 Replace the new fan, reconnect the shaft and bearings
and put the fan assembly in the cabinet.
8 Replace panels and fasteners.
Removing and Replacing the Coil
Removing Single Coils
Note: Single coils are bolted to the unit on the connection end.
The connection end is held in place with a clamp.
1 Disconnect all piping and remove the brass plugs for the
vents and drains located in the connections.
2 Remove all screws and remove the access panel.
3 Remove the screws holding the coil in place.
Removing and Replacing
Components
See Access Doors and Panels‚ page 8 for instructions on
removing panels and opening fan access doors to remove or
replace components.
WARNING
Before removing any component, lock out and tag out all
power to the unit. Fans and belts can cause severe personal
injury or death.
AVERTISSEMENT
Avant d’enlever toute composante, couper et indiquer que
l’alimentation électrique à l’unité est coupée. Les
ventilateurs et les courroies peuvent entraîner des blessures
personelles graves ou même la mort.
4 Lift and pull the coil out the side.
Installing Single Coils
1 Slide the coil through the opening in the coil section onto
the bottom coil rests.
2 To prevent any air bypass around the coil, place coils up
against the coil bulkheads. See Single Coil Top
Installation/Removal‚ page 31.
3 Once the coil is in place, fasten the coil to the section.
4 Caulk the seams between the coil casings and bulkheads.
5 If this is an additional coil being installed and not a
replacement, locate the coil supply and return
connections dimensionally. Carefully drill holes in the
end panels of the unit.
6 Remove the brass plugs for the vents and drains on the
connections.
Removing the Fan Section
7 Slip the panel over the connections.
The fan shaft, motor, and any drive components can be
removed and replaced through the access door opening. If
required, the side panel can be removed for additional access.
8 Replace the brass plugs and panel fasteners.
30
McQuay IM 777-6
Service and Maintenance
Figure 45: Single Coil Top Installation/Removal
Opposite
connection
end
Connection
end
Coil
Removing Stacked Coils
Note: Top and bottom stacked coils are held together with steel
plate and screws on one side and drain trough and
screws on the other side. Remove the plate and trough
before removing the coils. The coils cannot be removed
attached together.
1 Disconnect all piping and remove the brass plugs for the
vents and drains located in the connections.
2 Remove all screws and remove the access panel.
Coil
3 Remove the bolts holding the coil in place and then lift
and pull out the coil from the side.
4 Remove the steel plate and the drain trough that holds
the coils together.
5 Remove the bolts on both ends of the top coil holding it
in place and then lift and slide the coil out.
6 Remove the bolts on both ends of the bottom coil
holding it in place and then lift and slide the coil out.
Installing Stacked Coils
1 Slide the bottom coil through the opening in the coil
section onto the bottom coil rests.
2 Place the coil up against the coil bulkheads to prevent
any air bypass around the coil.
3 Once the coil is in place, bolt the coil to the section.
4 Caulk the mounting surface of the steel plate and install
the plate on the coils.
5 Caulk the mounting surface of the drain trough and
install the drain trough on the coils.
6 Caulk the seams between the coil casings and blockoffs.
7 Connect all piping and install the brass plugs for the
Figure 46: Single Coil Side Installation/Removal
Opposite connection end
Connection end
vents and drains located in the connections.
8 Install the access panel.
Removing and Installing Staggered Coils
Coil
Staggered coils have two banks of coils positioned a few
inches apart in the direction of airflow. Both coils are secured
to the unit on the connection and opposite connection end of
the unit.
Coil
1 Disconnect all piping and remove the brass plugs for the
vents and drains located in the connections.
Coil
Bulkhead
2 To access bolts holding the coils in place, remove the
panels on both the connection and opposite connection
end of the coil section.
3 Each coil is held in place with bolts located in the
corners of the coil side plates. Remove the bolts and then
lift and pull the coil out the side.
4 The bottom coil is fastened to the air block off plate.
Remove the screws attaching this plate to the coil.
Coil
Rests
5 Once the fasteners holding the coil in place are removed,
pull out the coil from either side of the unit.
6 Install the coils in reverse order of removal.
McQuay IM 777-6
31
Parts
Parts
Replacement Parts
When writing to McQuay for service or replacement parts,
refer to the model number and serial number of the unit
stamped on the serial plate attached to the unit. If replacement
parts are required, mention the date of installation of the unit
and date of failure, along with an explanation of the
malfunctions and a description of the replacement parts
required.
32
McQuay IM 777-6
Service and Warranty Procedure
Service and Warranty Procedure
Warranty
Consult your local McQuay Representative for warranty
details. Refer to Form 933-43285Y. To find your local
McQuay Representative, go to www.mcquay.com.
Warranty Return Material Procedure
Defective material may not be returned without permission of
authorized factory service personnel of McQuay International
in Minneapolis, Minnesota, (763) 553-5330. A “Return
Goods” tag must be included with the returned material. Enter
the required information to expedite handling and prompt
issuance of credits. All parts must be returned to the
McQuay IM 777-6
appropriate McQuay facility, designated on the “Return
Goods” tag. Transportation charges must be prepaid.
The return of the part does not constitute an order for
replacement. Therefor, a purchase order must be entered
through the nearest McQuay representative. The order should
include part number, model number, and serial number of the
unit involved.
Credit will be issued on customer's purchase order following
an inspection of the return part and upon determination that the
failure is due to faulty material or workmanship during the
warranty period.
33
Check, Test, and Start Procedure Form
Check, Test, and Start Procedure Form
To comply with the terms of McQuay Warranty, complete and return this form within 10
days to McQuay Warranty Department.
Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery.
Job Name:________________________________________ McQuay S.O. No.: _________________ McQuay G.O. No.: _________________
Installation address: __________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Purchasing contractor:________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Name of Person doing start-up (print)____________________________________________________________________________________
Company name _____________________________________________________________________________________
Address ___________________________________________________________________________________________
City/State/Zip _______________________________________________________________________________________
Unit model number: ________________________________________________ Unit serial number: _______________________________
SF VFD model number:_____________________________
RF VFD model number:_____________________________
Serial number: ___________________________________
Serial number: ___________________________________
N/A
N/A
Circle Yes or No. If not applicable to the type of unit, circle N/A.
I. INITIAL CHECK
A. Is any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
B. Are fan drives properly aligned and belts properly adjusted? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
C. Tightened all setscrews on pulleys, bearings and fans? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
D. Have the hold-down bolts been backed off on spring mounted fan isolators? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
E. With power off, do fans turn freely by hand? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
F. Electrical service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
G. Is the main disconnect adequately fused and are fuses installed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
H. Are all electrical power connections tight? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
I. Is the condensate drain trapped?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
J. Fill drain pan. Does water drain freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
K. Is the unit mounted level? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
A. Are blades and seals present?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
B. Do dampers open smoothly and shut tight?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Volts __________
Hertz __________
Phase __________
II. FAN DATA
A. Check rotation of supply fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Voltage at supply fan motor:
1–2 _________ V
C. Supply fan motor amp draw per phase:
2–3__________V
1–3 _________ V
L1____________
L2 ___________
L3 ___________
D. Overload amp setting: ______________
E. What is the supply fan rpm? ______________
F. Check rotation of return fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Voltage at return fan motor:
1–2 _________ V
H. Return fan motor amp draw per phase:
2–3__________V
1–3 _________ V
L1____________
L2 ___________
L3 ___________
I. Overload amp setting: ______________
J. What is the return fan rpm? ______________
K. Record supply static pressure at unit discharge: ______ inches of H20
L. Record return static pressure at unit (with outside air dampers closed)______________ inches of H20
III. DAMPERS
IV. ELECTRIC HEAT
A. Electrical heat service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
_________ Volts
_________Hertz
_________Phase
B. Are there any signs of physical damage to the electric heat coils? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
C. Have all electrical terminals been tightened?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
D. Does sequence controller stage contactors properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
E. Electric heater voltage across each phase:
L1–2________ V
L2–3 ________ V
L1–3 _______ V
Stage 3
Stage 4
Stage 5
____________
____________
F. Amp draw across each phase at each heating stage:
Stage 1
Phase L1:
34
___________
Stage 2
___________
___________
Stage 6
___________
McQuay IM 777-6
Check, Test, and Start Procedure Form
Phase L2:
___________
___________
____________
____________
____________
___________
Phase L3
___________
___________
____________
____________
___________
___________
G. FLA:
L1 ___________
L2 ___________
L3____________
H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control.. . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
B. Drain pan draining okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
A. Heat wheel rotates freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
B. Heat wheel VFD operates properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
V. CHILLED WATER COIL
VI. HOT WATER COIL
A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII. HEAT RECOVERY
C. Heat wheel VFD model #_____________________ serial #:_____________________ . . . . . . . . . . . . . . . . . . . . . . .
D. Check for air bypass around heat wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signature: ______________________________________________________
N/A
Startup date:____________________________________
RETURN COMPLETED FORM WITHIN 10 DAYS OF START-UP TO:
McQuay International Warranty Department, 13600 Industrial Park Boulevard, Minneapolis, MN 55441
Please list any additional comments that could affect the operation of this unit; e.g., shipping damage, failed components, adverse installation
applications, etc., on a separate sheet and attach to this form.
McQuay IM 777-6
35
Quality Assurance Survey Report
Quality Assurance Survey Report
Quality Assurance Survey Report
To whom it may concern:
Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the
product.
Job Name: _____________________________________________________
McQuay G.O. no. __________________
Installation Address: _____________________________________________________
City: __________________________________________________________
State: __________________
Purchasing Contractor: __________________________________________________
City:__________________________________________________________
State: __________________
Name of person doing start-up (print): _____________________________________________________
1. Is there any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
__Location on unit _____________________________________________________
2. How would you rate the overall appearance of the product; i.e., paint, fin damage, etc.?
Excellent
Good
Fair
Poor
3. Did all sections of the unit fit together properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
4. Did the cabinet have any air leakage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
N/A
Yes
No
N/A
Location on unit ___________________________________________________________________________
5. Were there any refrigerant leaks? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping
Workmanship
6. Does the refrigerant piping have excessive vibration?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design
Yes
No
N/A
Yes
No
N/A
Yes
No
N/A
Location on unit ___________________________________________________________________________
7. Did all of the electrical controls function at start-up? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments _______________________________________________________________________________
8. Did the labeling and schematics provide adequate information? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. How would you rate the serviceability of the product?
Excellent
Good
Fair
Poor
Good
Fair
Poor
Fair
Poor
10. How would you rate the overall quality of the product?
Excellent
11. How does the quality of McQuay products rank in relation to competitive products?
Excellent
Good
Comments:
Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed
components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a
separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty
Department with the completed preceding “Equipment Warranty Registration Form”.
36
McQuay IM 777-6
McQuay Training and Development
Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority.
For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training,
or call 540-248-9646 and ask for the Training Department.
Warranty
All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product
Warranty. Consult your local McQuay Representative for warranty details. Refer to Form 933-430285Y. To find
your local McQuay Representative, go to www.mcquay.com.
This document contains the most current product information as of this printing. For the most up-to-date product
information, please go to www.mcquay.com.
© 2011 McQuay International • www.mcquay.com • 800-432-1342
10/11