Carpigiani Vision Installation Manual

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Installation and Maintenance Manual IM672-4

Vision™Air Handler

Sizes 003–090

Group: Applied Air

Part Number: IM672

Date: Ju

ly 2007

Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3

Receiving and Handling. . . . . . . . . . . . . . . . . . . . . 3

Unit Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . 4

Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . 4

Rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembling Sections . . . . . . . . . . . . . . . . . . . . . . . 5

Ceiling Hung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Panels, Frame Channels, and Doors. . . . . . . . . . . 8

Field Mounting Junction Boxes and

Other Components. . . . . . . . . . . . . . . . . . . . . . . . . 9

Face and Bypass Section Mounting . . . . . . . . . . . 9

Multizone Assembly. . . . . . . . . . . . . . . . . . . . . . . 11

Duct Connections. . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . 13

Piping and Coils. . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drain Pan Traps. . . . . . . . . . . . . . . . . . . . . . . . . . 16

Internal Isolation Assembly Adjustment. . . . . . . . 16

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . 17

Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . 18

Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fan Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . 19

Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . . 23

Service and Maintenance . . . . . . . . . . . . . . . . . . . 24

Periodic Service and Maintenance . . . . . . . . . . . 24

Ball Bearing Lubrication. . . . . . . . . . . . . . . . . . . . 24

Fan Drive Adjustments. . . . . . . . . . . . . . . . . . . . . 24

Fan Drive Belt Adjustment . . . . . . . . . . . . . . . . . . 28

Front Load Filter Option . . . . . . . . . . . . . . . . . . . . 29

Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintaining the Coil . . . . . . . . . . . . . . . . . . . . . . . 30

Winterizing Water Coils . . . . . . . . . . . . . . . . . . . . 30

Removing and Replacing Components . . . . . . . . 30

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Warranty Return Material Procedure . . . . . . . . . . 33

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . 33

General Information

Vis ionTM air handlers are not designed to be weather resistant. Do not install them outdoors.

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.

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.

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.

Receiving and Handling

1 Carefully check items against the bills of lading to verify

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 Vision air handler units are constructed of galvanized or

painted steel and are inspected thoroughly before leaving the factory. Take care during installation to prevent damage to units.

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.

4 Handle the zone damper of the multi-zone units with

special care. Zone dampers are set and inspected before leaving the factory, but should be checked on arrival to the job to verify the bell arm and connecting rod set screws did not become loose in shipment.

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.

Unit Storage

Store unit on a level surface. If air handling units are stored for any period of time, periodically rotate the fan wheel to prevent permanent distortion of drive components. In addition, grease may settle in the lower part of the bearing, which can lead to oxidation on the upper portion of the bearing surface. Keep the fan bearings lubricated.

Store units indoors in a clean, dry environment on a level surface. Moisture, debris, and minerals can cause permanent damage to the cabinet and components. Do not allow coverings to trap moisture on the galvanized surface.

Nomenclature

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

CAH 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

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 672-4 3

Installation Guidelines

Service Clearances

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 shaft removal and coil removal. Space, at least equal to the length of the side coil, is required for coil removal. Space, at least equal to the fin height, is required for top coil. See Figure 1 for servicing space requirements.

For routine maintenance purposes, access normally is obtained through the access doors or by removing panels. Fan and filter sections are always provided with a service door on one side of the unit. If requested, 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.

If component replacement is required, the top panel also can be removed. If necessary, the unit can be disassembled. Maintain at least 54" of clearance in front of electrical power devices (starters, VFDs, disconnect switches and combination). Electrical power devices that are mounted on the side of the unit typically are up to 12" deep. See Figure 2.

Figure 1: Servicing Space Requirements

4 . 0 0 " b a s e r a i l e x t e n s i o n

Figure 2: Service Clearance for Electrical Power Devices

1 2 "

5 4 "

Rigging

Vision handlers ship as separate sections, completely assembled, or in modules of assembled sections.

be rigged as it ships from the factory. Do not rig units after assembly.

rail

When a unit is

, it

can be lifted using the 2" diameter lifting holes located in

provided with a factory-installed base

the corners of each shipping section. If a unit does not have a base rail, rig it using straps or a sling. Fasten the strapping under the skid that ships with the section.

The unit must

3 0 . 0 0 "

W i d t h

4 . 0 0 "

3 0 . 0 0 "

W i d t h o f c o i l s e c t i o n

W i d t h o f

f a n s e c t i o n

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.

Figure 3: Units on Base Rails

H e i g h t

4 McQuay IM 672-4

Installation Guidelines

)

S t a

Figure 4: Units on Skids

Fan sections greater than 108" wide that are stacked on another section are constructed with internal fan support frames that have integral lifting brackets. After the fan section is placed in position, remove and discard the lifting brackets. Install the small panels provided to complete the unit cabinet areas where the lifting brackets were located.

Figure 5: Fan Sections Stacked on Top of a Lower Section

Unit Leveling

Place the equipment on a flat and level surface. Where the surface irregularities allow the equipment to distort, shim the base of the unit a straight line. Uneven or distorted sections cause misfit or binding of the doors and panels and improper draining of drain pans.

Units that are over 108" wide must rest on a flat surface for the entire width of the base rails or must be shimmed at one or more points along the length of the rails to prevent distortion or sagging of the support rails. See Figure 6.

Figure 6: Leveling the Unit

h i m s e c t i o n s u n t i l

h e y a r e s t r a i g h t

n d l e v e l

S h i m t o p r e v e n t d i s t o r t i o n i f w i d t h i s o v e r 1 0 8 "

I n s t a l l p a n e l s ( 4 )

R e m o v e l i f t i n g b r a c k e t s ( 4

Assembling Sections

External Section-to-Section Mounting

Vision air handling units can ship fully assembled or as separate shipping sections. Rig units that require field assembly of shipping sections into position first. provided with a connection splice joint attached on the leaving air side of the shipping section. The splice joint is insulated and provides an air-tight seal between two sections once they are assembled together. If the splice joint was bent during shipping or rigging, restore it to its original position. See Figure 10.

Horizontal Airflow Section Mounting

1 Rig the unit into position and line shipping sections up in

direction of air flow.

2 Pull sections together to fasten. Use a furniture clamp or

straps and a ratchet to help pull the sections together securely. See Figure 7.

3 If the unit has a factory-installed base rail, first fasten base

rails together using the 3/8"-16 × 5" bolts located in the splice kit provided with the unit.

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.

Shipping sections are

McQuay IM 672-4 5

Installation Guidelines

4 If no base rail is provided, fasten the unit in the same

manner on the bottom and top frame channels.

5 Once the sections are positioned together, remove the

fastener in each of the channel corners (on the mating edges in the channel piece).

6 Place a flat section joining plate (found in the splice kit)

over the two coned holes in the channels, so that the plate spans the two sections.

7 Replace the fasteners in their original position, through the

joining plate.

Figure 7: Horizontal Joining Sections

T o p

B o t t o m w i t h b a s e r a i l

Vertical Inverted Airflow Section Mounting

For vertical or inverted arrangements, before lifting any top mounting sections into place, rig into place and fasten together the bottom tier of sections. Once bottom level sections are in place and secured, lift stacked components and fasten using the following procedure:

Note – See “Face and Bypass Section Mounting” on page 9 for

the exception to this procedure.

1 The vertical/inverted section has a splice joint extending

out the top of the bottom joining section. Lower the section that is to be positioned over the opening over the splice joint to seal the connection between the two sections.

2 The two sections are fastened together at the four bottom

corners of the mating edge. To fasten the corners located on the end of the unit (where bottom section and top section walls are flush with each other), remove the flat head fasteners in the corners of both sections.

3 Cover the coned holes with a flat joining plate and replace

the flat head fasteners in the holes to secure the joining plate to both sections. See Figure 8.

4 When one section is deeper than the other, secure the two

sections using an L-shaped joining plate. To secure the L-shaped bracket, remove the flat head fastener from the corner, position the bracket over the hole, and replace the flathead fastener with a 5/16"-18 × 1" bolt. Once the bolt is in place, secure the bracket to the adjoining section with a 1/4 × 1" drill screw. Repeat the same procedure on both corners of the unit. See Figure 8.

Figure 8: Vertical Inverted Joining Sections

. 3 1 2 - 1 8 x 1 0 0 b o l t

. 2 5 x 1 0 0 d r i l l s c r e w

R e p l a c e m e n t s c r e w

Extended Coil Section Mounting

The extended coil section is 6" wider than all other sections of the same unit size. The extension is always located on the coil connection side of the unit. Because the extended coil section is wider than other sections, it always ships as a separate shipping section, and must be joined to other sections in the field. To join an extended coil section to other components, first follow the horizontal airflow fastening steps on page 5 to secure the opposite connection side. To fasten the connection side, use the following procedure:

1 If the unit has a factory-installed base rail, the extended coil

section base rail is also 6" wider than the adjoining base rail. Extended coil section base rails on the connection side are fastened together using the 3/8"-16 by 3" bolts located in splice kit provided with the unit. See Figure 9.

2 If no base rail is provided, the section is fastened in the

same manner on the bottom and top. Once the sections are positioned together, remove the fastener in the corner of the channel piece of the section mating to the extended coil section. See Figure 9.

3 Place an L-shaped section joining plate (located in the

splice kit) over the coned hole in the channel.

4 Replace the flat head fastener originally used in the corner

with a 5/16"-18 1" bolt and fasten it through the L-shaped joining plate.

5 Position the L-shaped joining plate so it butts up against the

extended coil section frame channel. To secure the plate to the extended coil section, run two 1/4" × 1" drill screws through the joining plate and into the frame channel.

Figure 9: Extended Coil Section Joining

T o p

V i e w A

B o t t o m w i t h b a s e r a i l

( 2 ) 1 / 4 x 1 D r i l l S c r e w s

6 McQuay IM 672-4

Installation Guidelines

Internal Section-to-Section Mounting

If desired, shipping sections 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.

The section-to-section splice joint is always provided on the leaving air side of a shipping section and seals against the frame channel on the entering-air side of the adjoining section. 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. See Figure 10.

Figure 10: Internal Fastening

Ceiling Hung Using Angle Iron Channel

Install field-provided angle iron or channels per SMACNA guidelines. When a unit is unitized (ships in one piece), channel support each component under the unit width.

See Figure 12.

When a unit is sectionalized (ships in multiple sections), channel support each component under the unit width and provide support under the full length of the unit base.

See Figure 13. Locate

hanger rods so they do not interfere with access into the unit.

Ceiling suspension using the unit base rails is limited to unit cabinet widths less than 108". Support units with

cabinets 108" wide and greater with structural members designed to support the unit at the ends and at intermediate points along the base rails.

Figure 12: Ceiling Suspended w/o Base Rail (Unitized) Construction

S p l i c e C o l l a r m u s t b e a l i g n e d t o s e a l t o g a s k e t .

Ceiling Hung

When a unit is ceiling hung, support it with a base rail, angle iron, or channel. The Vision air handler is not designed to be suspended from the top of the unit. Before hanging, rig and completely assemble the unit. See “Assembling Sections” on page 5.

Ceiling Hung Using Base Rail

The optional base rail provided by the factory has 5/8" diameter holes in each corner to run hanger rods through. To properly support the unit and maintain unit integrity, support each shipping section with hanger rods in each corner. See Figure 11.

Figure 11: Ceiling Suspended with Base Rail

Figure 13: Ceiling Suspended w/o Base Rail—Modular Construction

McQuay IM 672-4 7

Installation Guidelines

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.

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. See Figure 14.

Figure 14: Removing Panel Screws

Remove any panel screws that engage frame

ATTE NTION

Les bords tranchants et les surfaces des bobines sont un risque de blessure. Ne les touchez pas.

CAUTION

DO NOT attempt to rotate the cup. Damage to the unit will occur.

ATTE NTION

NE PAS tenter de faire tourner la cuvette (cup). Ceci va dendomagger l’unité.

2 Insert 1/2" socket into cup and rotate 1/4 turn clockwise as

shown in Figure 15. If the cup and handle are on the left side of the door, rotate 1/4 turn counterclockwise.

3 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 cup and handle are on the left side of the door, rotate the door handle 1/4 turn counterclockwise and then 1/4 turn clockwise.

4 To prevent air leakage, tighten the door panels by adjusting

the jam nuts.

Remove panel to remove frame

Fan Section Doors

Note – Opening fan section doors requires using a 1/2" socket

wrench, which satisfies ANSI standards and other codes that require the “use of tools” to access compartments containing moving parts or electrical wiring. See Figure 15.

1 Remove padlock if one is present.

Figure 15: Opening Fan Section Door

Do Not Rotate Cup

Jam Nuts

View from inside door

OPEN

CAUTION

Sharp edges and coil surfaces are a potential injury hazard. Avoid contact with them.

8 McQuay IM 672-4

Installation Guidelines

Injected-Foam Insulated Panels

Vision 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.

Panel Cutting Procedure

1 Determine the number and location of holes required for

electrical conduit, piping, and control wiring as follows:

• Check that adequate space is available inside the unit for

conduit or pipe routing.

• Do not locate holes in a panel that provides access to key

maintenance components such as filters and fan assemblies.

• 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

Figure 16: Cutting/Sealing Injected-Foam Insulated Panels

Seal completely with silicone

Cut hole from both sides of panel

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.

sealant or duct seal compound

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 4, 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.

Face and Bypass Section Mounting

Internal face and bypass, and external face and bypass for sizes 003 to 035 are mounted together using the instructions for horizontal components and do not require additional instruction.

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.

For all size units that bypass directly into a vertical fan section and for sizes 040 to 090 with external face and bypass, use the following instructions.

Bypass Into a Vertical Fan Section

Vertical coil sections and the top mounted fan section always ship separately and must be mounted together at the job site. The vertical coil section and the bypass duct each has a joining collar mounted on the leaving air side of the section and duct, respectively. The mounting collar fits into the side (bypass) and bottom (vertical coil section) openings in the fan section. To correctly position the collars in the fan openings, assemble the fan and coil section first. Use the steps below for assembly. See Figure 17.

McQuay IM 672-4 9

Installation Guidelines

1 Place the vertical coil section in position. If an access

section is positioned downstream from the coil section and not already assembled to the coil section, secure the two sections together.

2 Lift the fan section on top of the vertical coil section, taking

care to line up the joining collar in the bottom of the fan section.

3 For sizes 003 to 035, the bypass duct is integral to the unit

construction and does not require attachment to the bypass section. For sizes 040 to 090, position and assemble the bypass duct to the bypass section before joining to the fan.

4 Once the fan is positioned on top of the vertical coil section

and the bypass duct and bypass section are assembled, position the two assemblies and line up the joining collars with the openings in the fan and vertical coil section.

5 Once the sections are lined up and in position, secure the

unit together by fastening joining plates to the unit.

Figure 17: Assembly of Fan Coil Sections

Joining collar

Unit Sizes 040 to 090 External Face and Bypass Duct Assembly

When unit sizes 040 to 090 are ordered with external face and bypass, the bypass duct ships separately and must be attached to the unit in the field. The joining of the bypass duct to the unit must be done after the unit is assembled. Also, if the bypass duct is over 90" long, the duct does not ship in one piece and must be field assembled. The field assembly of the bypass duct to the unit requires the following steps. See Figure 18.

1 Position the unit shipping sections together and assemble in

the equipment room.

2 After the unit is assembled, lift the duct into position over

the unit. Joining collars are shipped factory assembled to the unit and duct. There is a joining collar located in the top of the bypass opening and in the leaving air side of the bypass duct. These joining collars are used to provide air seals. Line up the duct with the top openings in the unit.

3 If the bypass duct is longer than 90", the duct ships in more

than one piece and must be field assembled. Place the piece of duct that has the joining collar on the bottom on top of the unit first. Once it is in place, position the other piece of duct. Take care to fit the splice collar into the first piece of duct and then lower the other end into the bypass opening.

4 Once the duct is positioned correctly, fasten the duct pieces

together with the joining plate provided. To do this, remove the fasteners in the corners of the duct assemblies, place the plate over the holes in the corners, and then replace the fasteners. See Figure 7 on page 6.

Figure 18: Assembly of Bypass Duct to Unit

J o i n i n g C o l l a r

10 McQuay IM 672-4

J o i n i n g C o l l a r

J o i n i n g C o l l a

Installation Guidelines

Multizone Assembly

The multizone section may ship completely assembled or it may ship in numerous pieces. Whether the section ships in a single piece or multiple pieces depends on customer requirements and the unit size. When a multizone section is over 90" high or 90" wide, split it into sections for shipping.

The unit may ship in 1, 2, 3, 4, or 5 separate pieces. Typically, the multizone damper assembly ships separately (see “Multizone Damper Assembly” in the next column and Figure 20 on page 12) and must be attached at the job site. Attach the damper after the other components are assembled. Use the instructions below for assembling the multizone section. See Figure 19.

1 If the diffuser and the cold deck section ship separately,

join them together first. The joining collar mounted in the diffuser fits into the entering air side of the coil section. Line up the two sections and fasten together.

Once the diffuser and cold deck sections are joined, lift the hot deck and bypass sections in place on top of the diffuser/ cold deck section. If possible, assemble the hot deck and bypass section (if there is one) together before lifting on top. There always is a joining collar in the diffuser. The joining collar provides the seal between the sections joints. It is important to line up and fit the collar in the hot deck and bypass section. For vertical applications, the cold deck also has a joining collar in the discharge opening. This collar fits in the bottom of the vertical bypass section.

3 After the components in the multizone are fitted together,

fasten the joining plates to the corners in the unit exterior.

4 If a damper was ordered, assemble it to the section (see

“Multizone Damper Assembly” in the next column and Figure 20 on page 12).

Note – Verify that the joining collars are aligned to seat into the

gasket. Straighten any collars distorted from shipping or from rigging.

Multizone Damper Assembly

When a multizone unit is ordered with dampers, depending on the multizone configuration and size, the damper assembly may ship separately (all horizontal and units with a total height over 90").

When the dampers are not factory assembled to the unit, they ship to the job site on a skid. An assembly kit with screws and an instruction drawing are included with the damper for field assembly to the unit.

To assemble:

1 First remove the side plate that encloses insulation from

both sides of the damper assembly.

2 Lift the damper assembly into position. See Figure 20.

3 Fasten the assembly to the frame channels within the

multizone openings.

4 Use caulking to seal up the areas around the unit frame

channel to prevent any air leakage.

5 After caulking, put the side plates back in place and secure.

Damper shaft extensions are provided on both ends of the damper assembly for actuation. The dampers are linked together by a linkage bar on both ends of the damper. The linkage bar is cut at the time of installation to divide the damper into the required number of zones. See “Multizone Damper Adjustment” on page 12.

Figure 19: Multizone Sections Assembly

Zone damper assembly

Upper unit—heating

Joining collars

Cooling coilCooling coilDiffuser

McQuay IM 672-4 11

(and optional bypass)

Installation Guidelines

Figure 20: Multizone Damper Assembly

A i r f l o w R i g h t h a n d c o i l

D a m p e r b l a d e s b r o k e n o u t t o s h o w a i r f l o w b a l a n c e p l a t e s b e h i n d t h e m .

R e m o v e a s s e m b l y i n s u l a t i o n p a n e l c o v e r f r o m d a m p t o a l l o w c a u l k i n g .

e r

D r i l l s c r e w i n t o c a b i n e t f r a m e w i t h # 1 0 A B x . 5 0 d r i l l s c r e w .

S e a l w i t h c a u l k o n b o t h s i d e s .

Duct Connections

Use flexible connectors on the outlet and inlet duct connections of all units. Each zone divider has a W-shaped duct clip. Insert ductwork into this clip. Figure 21.

Figure 21: Duct connectors

D u c t w o r k

Note – Before connecting to ductwork, read “Multizone Damper

Adjustment” below.

Multizone Damper Adjustment

The installer must clear the damper assemblies of construction dirt and debris. These materials result in higher torque requirements and may bend or damage damper components.

Before you begin:

1 Verify that dampers are square and operating smoothly

before ducting.

D u c t c l i p

Z o n e d i v i d e r

I f a i r f l o w b a l a n c e p l a t e s a r e p r e s e n t , t h e n i n s t a l l d a m p e r s s o t h a t t h e p l a t e s a r e o n t h e b o t t o m o f e a c h z o n e .

1 / 4 A B x . 5 0 O p e n d a m p t o a l l o w f a s t e n i n g .

e r b l a d e s

b a l a n c e

2 Install duct access panels on the downstream damper for

inspection and maintenance.

If multizone dampers do not close properly, adjust the blades as follows:

1 Loosen set screws in bell arms for all zones.

2 Close all cold deck dampers tightly.

3 Move bell arms so they are at a 45° angle to the vertical

center when viewing the zone dampers from the cold deck end of the damper section. See Figure 22.

a Two-deck zone dampers—The cold deck closes when

the bell arms are 45° from the vertical center. The hot deck closes when the bell arms are 45° clockwise from the vertical center.

b Three-deck zone dampers—The cold deck closes when

the bell arms are 45° clockwise from the vertical center. The hot deck closes when the bell arms are 45° counterclockwise from the vertical center.

4 Tighten set screws on bell arms while holding the dampers

closed.

5 All zone damper blades should close properly. If one or a

few zones do not close completely, repeat the procedure for these zones.

12 McQuay IM 672-4

Figure 22: Bell Arms at 45° Angle to Vertical Center

Z o n e d a m p e r l i n k a g e

C o n n . l i n k

4 5 °

B e l l a r m

Installation Guidelines

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.

I n s t a l l a t i o n m o d i f i c a t i o n f o r m u l t i p l e z o n e s

4 5 °

To divide the damper section into multiple zones, cut and remove sufficient connecting link to allow adjacent zones to operate independently.

Note: The damper blades on two-deck dampers seal through several degrees of shaft rotation.The damper blades can rotate 360° and do not engage a stop. The hot deck blades are mounted at a 90° to the cold deck blades. Before installing the zone duct, set up linkages and dampers and adjust. If adjustment is required and access to the blades is restricted, observe the cold deck blade position by removing the cabinet panel on the coil section.

4 5 °

B e l l a r m

Multizone, Mixing Box and Economizer Damper Torque Requirements

On multizone units, the actuator must drive the connection link for proper damper actuation. Do not activate multiple dampers must from the shaft extension opposite the connection link.

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.

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.

Face Bypass Damper Torque Requirements

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.

Unit sizes 040 to 090 provided with external face and bypass, require three actuators. Other arrangements with stacked or staggered coils require two actuators. A damper shaft extension is provided. The shaft extension normally is located on the drive side of the unit, but can be moved to the other side.

Face and bypass dampers have a torque requirement of 10 in-lbs per square foot of damper face area.

Piping and Coils

When designing and installing piping:

• 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

• 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.

• 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.

McQuay IM 672-4 13

Installation Guidelines

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. Do not apply heat to the body of the expansion valve.

• 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.

Steam Coils (see Figure 23 on page 15)

Piping

• All steam coils in units are pitched toward return connection.

•

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.

• 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

• Install vacuum breakers on all applications to prevent retaining condensate in the coil. Generally, the vacuum breaker is connected 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.

• Do not drip supply mains through the coil.

• Do not attempt to lift condensate when using modulating or

on/off control.

Traps

• 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.

• Multiple coil installation.

– Individually trap each coil or group of coils that is

controlled individually trapped.

– Coils in series—use separate traps for each coil, or a bank

of coils.

– 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.

• Freezing conditions (entering air temperatures below 35°F).

– McQuay strongly recommends 5JA, 8JA, 5RA and 8RA

coils.

– Supply 5 psi steam to coils at all times.

• Do not use modulating valves. Provide control by face and bypass dampers.

– 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.

– 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.

14 McQuay IM 672-4

Figure 23: Piping Arrangements

Installation Guidelines

Float and

thermostatic trap

Vacuum breaker 1/2" check valve

1/4" petcock for continuous air venting

1" min.

12" min.

5GA or 8GA coils. Note that the addition of a vacuum breaker to permit the coil to drain during shutdown.

Check Valve Strainer Gate Valve

High Pressure (over 25 psi)

Steam main

Return main

1/4" petcock for continuous

High pressure float or bucket trap

Return main

air venting

High pressure bucket trap

5TA, 8TA, or 5HA coils. Condensate is lifted to overhead return main

Low Pressure (to 25 psi)

Vacuum breaker 1/2" check valve

1" min.

Control valve

modulating

two position

12" min.

Full size of return conn.

Steam main

5J, 5G, 8J or 8G coils.

Steam main

Vacuum breaker 1/2" check valve

Return main

Vacuum breaker 1/2" check valve

12" min.

Full size of return conn.

Steam main

12" min.

5JA or 8JA coil. Installed in series. Note that each coil must have a separate control valve and trap.

Return main

Steam main

Vacuum breaker 1/2" check valve

Return main

5RA, 8RA, or 5SA coils. Banked two high, individual trapping of each coil as shown is preferred.

5RA, 8RA, or 5SA coils. Installed

McQuay IM 672-4 15

Installation Guidelines

Water Heating Coils

CAUTION

Improper installation, use, or maintenance of water heating coils can cause equipment damage. Read and

follow instructions carefully.

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.

• 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.

• To prepare coils for winter operation, see “Winterizing Water Coils” on 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. See Figure 24.

Figure 24: Allow Adequate Distance Between Trap Outlet

and Drain Pan Outlet

Pressure (P)

at the drain pan

Internal Isolation Assembly Adjustment

On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment..

Before Operating the Unit:

Remove the shipping brackets and tie-down bolts (see 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 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: Spring Mount Adjustments

Spring mount adjustment at rest

Fan discharge position Top or bottom horz. (dim "H")

Unit sizes 003–035

13.75

24.25

34.25

43.75 Unit sizes 040–-090

16.00

26.50

36.50

46.00

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. See Figure 25.

Figure 25: Adjusting Large Spring Mount Assembly

Adjusting bolt

16 McQuay IM 672-4

Installation Guidelines

Figure 26: Removing Shipping Brackets

Unit sizes 006 - 090

Electrical Installation

Wiring

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,

S h i p p i n g b r a c k e t

e m o v e a n d d i s c a r d

( T y p i c a l 4 p l a c e s )

D i m " H "

P O S 3

M o t o r

P O S 4

F a n i s o l a t o r p o s i t i o n n u m b e r s

S p r i n g h e i g h t a d j u s t m e n t s c r e w

S h i p p i n g b r a c k e t

S h i p p i n g h o l d d o w n r e m o v e a n d d i s c a r d ( T y p i c a l 4 p l a c e s )

S e e d e t a i l " A "

S p r i n g h e i g h t a d j u s t m e n t s c r e w

P O S 2

A i r f l o w

F a n

P O S 1

S h i p p i n g h o l d

d o w n s c r e w

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.

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

D e t a i l A

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.

• A door electrical interlock is not provided as standard.

• Thermal motor protection is external to the unit. Unless the

unit is provided with a variable frequency drive (VFD) or a unit mounted starter, thermal protection and a disconnect switch provision per electric codes are provided by others.

• When the unit is factory provided with a junction box, disconnect switch, starter, or a variable frequency drive (VFD), the components are mounted on the outside of the unit cabinet. Factory wiring is provided from the device to the unit internal motor.

• When the unit is provided with a VFD only, refer to the VFD manual for wire size and torque requirements.

McQuay IM 672-4 17

Operation Guidelines

Startup Checks

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.

ATTENTION

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).

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.

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.

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).

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

terminated.

4 Check that all electrical connections are tight and that the

proper voltage is connected. Phase imbalance must not exceed 2%.

5 Do not grease ball bearings on the fan shaft and motor

before startup. They are prelubricated.

6 Check tightness of setscrews in bearings and fan wheel(s).

If retightening is needed, position the fan wheel(s) per Table 2 or Table 3 on page 19. Torque set screws per

Table 6 on 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.

7 Check alignment of fan and motor sheaves and belt tension.

Adjust if necessary. Check tightness of sheave setscrews and/or capscrews. See Figure 39 and Figure 40 on page 28.

8 Leak test the thermal system to verify that connections are

tight.

9 Check that the condensate drain is trapped.

10 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 672-4

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 Adjustments” on page 24.

After the First 48 Hours of Operation:

1 Disconnect and lock electrical power source.

2 Check tightness of all bearing, wheel, and sheave setscrews

(or capscrews). See Table 6.

Recheck belt tension and adjust if necessary. Belts that are 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.

Fan Wheel Alignment

Figure 27: Wheel-to-Inlet Tunnel Relationship—Airfoil Type

Fan Wheels (Housed)

E q u a l s p a c i n g

a l l a r o u n d

Table 3: Wheel-to-Inlet Funnel Relationship—Forward Curved Type Fan Wheels

Forward curved

Unit sizes 003 to 035 Unit sizes 040 to 090

Diameter (in)

9 x 4 0.25 6.35 20 (Class 1 & 2) 0.24 6.10 9 x 7 0.13 3.30 22.38 (Class 1 & 2) 0.41 10.41 9 x 9 0.25 6.35 25 (Class 1 & 2) 0.47 11.94

10 0.22 5.59 27.62 (Class 1 & 2) 0.47 11.94 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

Notes:

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

(in)C (mm)

Diameter (in)

(in)C (mm)

Figure 29: Wheel-to-Inlet Funnel Relationship—Plenum

Fans

Table 2: Wheel-to-Inlet Funnel Relationship—Airfoil Type

Airfoil

Unit sizes 003 to 035 Unit sizes 040 to 090

Dia.

(in)A (mm)B (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 5.62 143 0.21 5.33 24.50 8.56 217 0.31 7.87

17.69 6.90 175 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

Notes:

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 re-torquing fasteners.

Dia.

(in)A (mm)A (in)B (mm)

Figure 28: Wheel-to-Inlet Funnel Relationship—Forward

Curved Type Fan Wheels

I n l e t

F u n n e l

W h e e l

I n l e t

F u n n e l

verlap

Table 4: Wheel-to-Inlet Funnel Relationship—Plenum Fans

Wheel—funnel overlap

Size Overlap

13.5 .120 15 .190

16.5 .250

18.25 .310 20 .380

22.25 .440

24.5 .500 27 .560 30 .620 33 .750

36.5 .810

40.25 .880

44.5 .940 49 1.000

54.25 1.060 60 1.120

McQuay IM 672-4 19

Operation Guidelines

Figure 30: Wheel-to-Inlet Funnel Relationship—Inline Fans

Overlap

Table 5: Wheel-to-Inlet Funnel Relationship—Inline Fans

Wheel—funnel overlap

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 6: Bearing Collar and Wheel Hub Set Screw Torque

set screw Minimum torque

Diameter (in) ft/lbs kg/m.

1/4 5.5 .76

1/16 10.5 1.45

3/8 19.0 2.63

7/16 29.0 4.01

1/2 42.0 5.81 5/8 92.0 12.72

20 McQuay IM 672-4

Operation Guidelines

Operating Limits

Do not exceed the operating limits in Table 7. 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 7: 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 24.50 Maximum rpm Class I N/A 2189 2223 1934 1614 1328 1155 1050 944 858 Maximum rpm Class Il 2244 2854 2896 2518 2091 1725 1450 1200 1030 910 Airfoil—housed 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

Figure 31: Torque for FC Variable Inlet Vanes (in–lb) Figure 32: Torque for AF Variable Inlet Vanes (in–lb)

500

400 350 300

250

200

150

Torque (in–lb)

100

90 80

200

250

300

350

Fan speed (rpm)

400

FC36.00

500

450

FC33.00

FC30.25

FC27.62

600

650

550

FC25.00

750

700

800

FC22.38

850

900

1000

FC20.00

1500

450 400

350 300 250

200 150

100

90 80 70

Torque (in–lb)

60 50 40 35

750

800

850

900

1000

AF24.00

AF21.56

1500

Fan speed (rpm)

2000

AF19.69

AF16.19

2500

AF14.56

AF13.22

3000

3500

4000

4500

Table 8: 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

McQuay IM 672-4 21

Operation Guidelines

Figure 33: Torque for FC Variable Inlet Vanes (in–lb)

300 250

FC24.50

800

850

FC22.25

900

1000

FC20.00

FC18.00

FC15.00

FC12.62

1500

200

150

100

Torque (in–lb)

80 70

60 50

350

400

450

500

600

650

700

550

Fan speed (rpm)

750

2000

Figure 34: Torque for AF Variable Inlet Vanes (in–lb)

2000 1500

1000

900 800

700 600

500 400

350 300

Torque (in–lb)

250 200

150

100

550

600

650

700

750

800

850

AF40.25

900

1000

Fan speed (rpm)

AF38.50

AF33.00

1500

AF30.00

AF27.00

AF24.50

AF22.25

2000

AF20.00

2500

Table 9: Operating Limits—Plenum Fans

Fan operating limits

Plenum fans

Diameter 13.5 15 16.5 18.25 20 22.25 24.5 27 30 33 36.5 40.25 44.50 49 54.25 60 Maximum rpm Class I 2895 2589 2376 2256 2077 1875 1691 1479 1328 1209 1073 972 882 799 725 651 Maximum rpm Class II 3786 3384 3100 2959 2703 2413 2199 1928 1730 1579 1401 1264 1150 1043 938 847 Maximum rpm Class III 4000 4000 3887 3735 3409 3065 2780 2423 2182 1984 1756 1598 1447 1314 1178 1071

3000

Table 10: 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

Twin fans

Diameter 9 x 9 10.62 12.62 15 18.12 20

Maximum rpm 2575 2400 2000 1700 1400 1200

Maximum HP 10 15 15 30 40 40

22 McQuay IM 672-4

Operation Guidelines

Figure 35: Torque Requirements at 100% WOV for SWSI Plenum Fans with NESTED Inlet Vane

5000

4000

3000

2000

1000

Torque (lb./in.)

900

Torque (in-lb)

800 700

600

500

400

300

200

100

600

200

300

400

700

500

Fan Speed (rpm)

800

900

1000

1500

Fan Vibration Levels

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 11.

Table 11: Vibration Levels

Fan speed (rpm) Vibration

800 or less 5 mils maximum displacement

801 or greater 0.20 in/sec. maximum velocity

Note: 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.

Vibration Causes

1 Wheel imbalance

a Dirt or debris on wheel blades

b Loose set screws in wheel hub or bearing-to-shaft

2000

3000

c Wheel distorted from overspeed

2 Bent shaft

3 Drive faulty

a Variable pitch sheaves—Axial and radial runout of

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

McQuay IM 672-4 23

Service and Maintenance

Periodic Service and Maintenance

1 Check all moving parts for wear every six months.

2 Check bearing collar, sheave, and wheel hub setscrews,

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

1 Motor bearings—All ball bearings are prelubricated and do

not require additional grease at time of installation. However, periodic cleaning out and renewal of grease is necessary. Exercise extreme care to prevent foreign matter from entering the bearing. It also is important to avoid over greasing. Use a high grade, clean mineral grease with the following characteristics:

• Melting point over 302°F (150°C)

• Free from oil and soap separation under operating and

storage conditions

• Free of abrasive matter, acid, alkali and moisture

Specific greasing instructions are located on a label attached to the fan section door.

2 Fan shaft bearings—All ball bearings are prelubricated and

do not require addition of grease at time of installation. However, periodic renewal of grease is necessary. Bearings are accessible through access door in fan section. Grease fittings are located in front of door opening on drive end of blower section. Apply grease slowly until a very slight bleeding of grease from the seals is noted. Tie hinged door(s) open. Do not over lubricate. Wipe off any excess grease to prevent overheating.

The lubrication interval varies with the period of operation and temperature of the ambient air. Use the guidelines in the table below.

Table 12: Lubrication Guidelines

Bearing operating temp range

Temperature

Continuous operation 6 months 4 months 2 months

12-hr. day operation 12 months 12 months 6 months

to 130°F

(54°C)

to 150°F

(66°C)

over 150°F

(66°C)

Table 13: Lubricants Recommended for Fan Shaft Ball Bearings

Manufacturer Product name

Texaco Lubricants Company Premium RB –30 to 300 –34 to 149 Keystone Ind. Lubricants 81EP-2 0 to 250 Mobil Oil Corporation Mobilith SCH100 Chevron U.S.A. Inc. SRI-2 Exxon Company, U.S.A. Ronex MP Shell Oil Company Alvania No. 2

Note: Temperature ranges over 225°F are shown for lubricants only. High

temperature applications are not suitable for standard air handler components.

Tem p. r ang e

°F °C

–

18 to 121

–

40 to 350–40 to 177

–

20 to 325–29 to 163

–

40 to 300–40 to 149

–

20 to 240–29 to 116

Fan Drive Adjustments

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.

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.

Moving parts and

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 ×

24 McQuay IM 672-4

Measured diameter at motor sheave Measured diameter at fan sheave

Service and Maintenance

VM and VP Variable Pitch Key Type Sheaves

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 turns for

3 Replace external key E and securely tighten setscrews B

over key and setscrews

B belts.

C into keyway in fixed half of the

A belts or six full

sheave.

4 Put on belts and adjust belt tension. Do not force belts

over grooves. See “Fan Drive Belt Adjustment” on 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 36: VP Type Sheave Adjustment

Single Groove

Key E projects to provide a grip for removal.

Two Groove

Do not operate

sheeves with flange projecting beyond the hub end.

McQuay IM 672-4 25

Service and Maintenance

LVP Variable Speed Sheaves

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.

2 When setscrew A is at an angle in the center flange B,

mount it away from the motor so that the outer locking ring and flange can be removed to get to the setscrew.

3 To remove the flange and locking ring:

a Loosen setscrews D.

b Loosen but do not remove capscrews E.

c Remove key F.

Note: This key projects a small amount to provide a grip

for removing.

d Rotate the flange counterclockwise until it disengages

the threads on the sheave barrel.

4 Verify that the driving and driven sheaves are in alignment

and the shafts are parallel. When aligning two-groove sheaves, allow room between the sheave and motor to access capscrews

5 Insert key C between the sheave and the shaft and tighten

setscrew

6 If flange and locking ring have been removed, when

A securely.

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.

7 Insert key F.

8 Tighten setscrews D and capscrews E.

9 Put on belts and adjust belt tension. Do not force belts

over grooves. See

“Fan Drive Belt Adjustment” on page

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.

Adjusting

1 Slack off belt tension if belts have been installed.

2 Loosen setscrews D.

3 Loosen but do not remove capscrews E.

4 Remove key F.

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.

Note: Two-groove sheaves are supplied with both grooves

set at the same pitch diameter.

To provide the same pitch diameter for satisfactory operation, move both movable flanges the same number of turns. Do not open sheaves more than five turns for or six turns for

6 Replace key F.

7 Tighten setscrews D and capscrews E.

8 If belts have been installed, readjust belt tension. If belts

B belts.

A belts

have not been installed, install them and adjust belt tension. Do not force belts over grooves. See “Fan Drive Belt Adjustment” on page 28.

9 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 operation.

Note – Replace variable speed sheaves for 15 hp motors and

greater with a fixed pitch sheave after air balancing to maintain fan balance integrity. Fixed sheaves furnished by others.

Figure 37: LVP Type Sheave Adjustment

Section A-A Section A-A

26 McQuay IM 672-4

Service and Maintenance

MVP Variable Speed Sheaves

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 38.

2 Verify that all setscrews are torqued to the values shown in

Table 14 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.

4 Any pitch diameter can be obtained within the sheave

range. One complete turn of the outer locking ring changes the pitch diameter 0.233".

5 Do not open sheaves more than the following:

• Do not open B sheaves more than 4 3/4 turns for the A

belts or 6 turns for the B belts.

• Do not open C sheaves more than 9 1/2 turns.

• Do not open 5V sheaves more than 6 turns.

• 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 14.

Replace belts and adjust the motor base to tension the belts properly. See “Fan Drive Belt Adjustment” on 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 14: Screw Torque Values

Socket head cap screws

Nominal screw size

(dia–-thds/in)

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

3/8–16NC 545 45.4 350 290 24.2 1/4, 5/16 150, 250 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

Seating torque Seating torque Seating torque Seating torque Length (L) Seating torque

(in–lbs) (in–lbs) (in–lbs) (in–lbs) (in–lbs) (in–lbs) (in–lbs)

Flat head socket

screws

Lengths equal or greater than dia. For lengths (L)) less than dia.

Hollow head set screws only

Figure 38: Sheave Adjustment

Must be parallel

Bearing

Motor

Must be parallel

Center lines must coincide

Adjustable Sheave

McQuay IM 672-4 27

Service and Maintenance

Figure 39: Sheave Adjustment

A d j u s t a b l e C e n t e r - F l a n g e

S p l i t T a p e r B u s h i n g

F i x e d C e n t e r - F l a n g e

( 2 ) L o c k i n g S e t s c r e w s " A "

F l a t h 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 )

C a p s c r e w s ( D o N o t R e m o v e )

Fan Drive Belt Adjustment

General Rules of Tensioning

1 The ideal tension is the lowest tension at which the belt

does not slip under peak load conditions.

2 Check tension frequently during the first 24 to 48 hours of

operation.

3 Over tensioning shortens belt and bearing life.

4 Keep belts free from foreign material that can cause

slippage.

5 Inspect V-drive on a periodic basis. Adjust tension if the

belt is slipping. Do not apply belt dressing. This can damage the belt and cause early failure.

Tension Measurement Procedure

1 Measure the belt span. See Figure 40.

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.

3 Compare this force to the values in Table 15.

Figure 40: Drive Belt Adjustment

Deflection =

Belt span

pan

S t a t i o n a r y E n d - F l a n g e

O u t e r

L o c k i n g - R i n g

I n n e r L o c k i n g - R i n g

( 3 ) H o l e s f o r S p a n n e r W r e n c h o r D r i f t

WARNING

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

always in place.

• Lock and tag out fans to prevent accidental start up.

• Do not enter the filter compartment until the fan is

completely stopped.

• Use approved equipment for reaching filters located above normal reach. Do not step on filter frames or unit components.

• Floor surfaces must be dry and free of oil or grease.

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.

• S’assurer que les gardes de courroie et de ventilateur sont

toujours en place.

• Verouiller les démarreurs des ventilateurs et afficher un avis de mise-en-garde afin de prévenir tout accident ou démarrage.

• Attendre que le ventilateur soit complètement arrêté avant 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.

• La surface des planchers doit être sec et libre de toute trace d'huile et où de graisse.

28 McQuay IM 672-4

Table 15: Belt Deflection Force (per Browning® specifications)

Sheave diameter (in) Deflection force (lbs)

Cross

section

A, AX

B, BX

5V, 5VX

Smallest

sheave

diameter range

3.0 to 3.6

3.8 to 4.8

5.0 to 7.0

3.4 to 4.2

4.4 to 5.6

5.8 to 8.6

4.4-6.7

7.1-10.9

11.8 -16. 0

rpm

range

1000 to 2500 3.7 5.5 4.1 6.1 2501 to 4000 2.8 4.2 3.4 5.0

100 to 2500 4.5 6.8 5.0 7.4 2501 to 4000 3.8 5.7 4.3 6.4 1000 to 2500 5.4 8.0 5.7 9.4 2501 to 4000 4.7 7.0 5.1 7.6

850 to 2500 4.9 7.2 2501 to 4000 4.2 6.2

860 to 2500 5.3 7.9 7.1 10.5 2501 to 4000 4.5 6.7 7.1 9.1

860 to 2500 6.3 9.4 8.5 12.6 250 to -4000 6.0 8.9 7.3 10.9

500-1749 10.2 15.2 1750-3000 8.8 13.2 3001-4000 5.6 8.5

500-1740 12.7 18.9 14.8 22.1 1741-3000 11.2 16.7 13.7 20.1

500-1740 15.5 23.4 17.1 25.5 1741-3000 14.6 21.8 16.8 25.0

Cross section A, B, 5V Cross section AX, BX, 5VX

Used belt New belt Used belt New belt

Service and Maintenance

Front Load Filter Option

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. See Figure 41.

Figure 41: Frame and Filters with Holding Clips

F i n a l F i l t e r

F i l t e r

P r e f i l t e r

R o t a t e W i r e C l i p s

F r a m e

Filter Gauges

Filter gauges indicate pressure drop for installed filters.

Table 16 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.

Where a single filter gauge is used, the prefilters can be removed to check the pressure drop of the final filters.

Figure 42: Filter Gauge

McQuay IM 672-4 29

Service and Maintenance

Table 16: Filter Pressure Drops

Bag filters—DriPak 2000

Efficiency 45% 65% 85% 95% Rated velocity (fpm) 625 500 500 500 Initial pressure drop .20–.26 .21–30 .34–.48 .50–.70 Initial pressure drop 1.0 1.0 1.0 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 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

Efficiency N/A Rated velocity (fpm) 500 Initial pressure drop .25 Final pressure drop 1.0

Pleated 62 Plus filters

Size 2" 4" Efficiency 70% 70% Initial pressure drop .42 .37 Final pressure drop 1.0 1.0

Maintaining the Coil

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.

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. 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 sufficient 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.

Removing and Replacing 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.

Removing a Panel

To remove a side or top panel:

1 Remove the flat head fasteners located along the sides of

the panel.

2 Once all fasteners are removed, lift off the panel.

Removing a Frame Channel

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:

1 First remove any adjoining side and top panel(s).

2 Once the side panel is off, remove the flat head fasteners in

the corner of the frame channels.

30 McQuay IM 672-4

Service and Maintenance

3 Pull the frame channel out the side.

If any top panel fastens into the frame channel (when the frame channel is 24" or wider in direction of air flow), remove the fasteners in the top panel before pulling out the channel.

Removing the Fan Section

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.

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

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.

2 Remove all screws and remove the access panel.

3 Remove the screws holding the coil in place.

4 Lift and pull the coil out the side.

Installing Single Coils

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 Figure 43.

3 Once the coil is in place, fasten the coil to the section.

4 Caulk the seams between the coil casings and bulkheads.

See Figure 43.

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.

7 Slip the panel over the connections.

8 Replace the brass plugs and panel fasteners.

Figure 43: Single Coil Top Installation/Removal

Opposite

connection

end

Coil

Connection

end

Coil

Removing and Replacing the Coil

The coil can be removed by the side, top, or a combination of both. The size and configuration of the coil affects how the coil can be removed. Single banks of coil are fastened only on the connection side of the unit. Stacked and staggered coils are fastened on both ends of the coil. See the instructions below for details to remove each coil type.

Before removing the coil, disconnect all piping. The instructions below assume the coil is mounted in a sectionalized coil section where the frame channel can be removed without affecting other components. If the coil section is unitized with other components, removing the top frame channel requires removing additional panels.

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.

McQuay IM 672-4 31

Service and Maintenance

Figure 44: Single Coil Side Installation/Removal

Opposite connection end

Coil

Coil Bulkhead

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

Connection end

Coil

Coil Rests

vents and drains located in the connections.

2 Remove all screws and remove the access panel.

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 vents

and drains located in the connections.

8 Install the access panel.

Removing and Installing Staggered Coils

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.

1 Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.

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.

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.

32 McQuay IM 672-4

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 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. Therefore, 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.

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.

McQuay IM 672-4 33

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 933-43285Y. 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.

Carpigiani Vision Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Receiving and Handling

Unit Storage

Installation Guidelines

Service Clearances

Rigging

Unit Leveling

Assembling Sections

Ceiling Hung

Panels, Frame Channels, and Doors

Field Mounting Junction Boxes and Other Components

Face and Bypass Section Mounting

Multizone Assembly

Duct Connections

Mounting Actuators

Piping and Coils

Drain Pan Traps

Internal Isolation Assembly Adjustment

Electrical Installation

Operation Guidelines

Startup Checks

Fan Wheel Alignment

Operating Limits

Fan Vibration Levels

Service and Maintenance

Periodic Service and Maintenance

Ball Bearing Lubrication

Fan Drive Adjustments

Fan Drive Belt Adjustment

Front Load Filter Option

Filter Gauges

Maintaining the Coil

Winterizing Water Coils

Removing and Replacing Components

Warranty

Warranty Return Material Procedure

Replacement Parts