McQuay CAC003G Installation Manual
Installation and Maintenance Manual IM 672-8
Vision™ Air Handler
Models CAC/CAH 003G – 090G
Group: Applied Air Systems
Part Number: IM 672
Date: November 2011
© 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
Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembling Sections . . . . . . . . . . . . . . . . . . . . . . . . .7
External Section-to-Section Mounting . . . . . . . . . . . .7
Horizontal Airflow Section Mounting . . . . . . . . . . . . . .7
Vertical Inverted Airflow Section Mounting . . . . . . . . . 8
Extended Coil Section Mounting . . . . . . . . . . . . . . . . 8
Side-by-Side Heatwheel Section Joining . . . . . . . . . .9
Internal Section-to-Section Mounting . . . . . . . . . . . .10
Ceiling Hung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Panels, Frame Channels, and Doors . . . . . . . . . . . . 11
Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Frame Channel Removal . . . . . . . . . . . . . . . . . . . . . 11
Fan Section Doors . . . . . . . . . . . . . . . . . . . . . . . . . .12
Injected-Foam Insulated Panels . . . . . . . . . . . . . . . . 12
Field Mounting Junction Boxes and
Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Face and Bypass Section Mounting . . . . . . . . . . . . 13
Bypass Into a Vertical Fan Section . . . . . . . . . . . . . 13
External Face and Bypass Duct Assembly
(Sizes 040 to 090) . . . . . . . . . . . . . . . . . . . . . . . . . .14
Multizone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 15
Multizone Damper Assembly . . . . . . . . . . . . . . . . . .15
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Multizone Damper Adjustment . . . . . . . . . . . . . . . . . 17
Multizone, Mixing Box and Economizer
Damper Torque Requirements . . . . . . . . . . . . . . . . . 17
Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Face Bypass Damper Torque Requirements . . . . . . 18
Isolation Dampers for Multiple Fans . . . . . . . . . . . . .18
Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Water Cooling Coils . . . . . . . . . . . . . . . . . . . . . . . . . 18
Direct Expansion Coils . . . . . . . . . . . . . . . . . . . . . . .18
Steam Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Water Heating Coils . . . . . . . . . . . . . . . . . . . . . . . . .21
Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Internal Isolation Assembly Adjustment . . . . . . . . 21
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Before Starting the Unit . . . . . . . . . . . . . . . . . . . . . . 25
VFD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fan Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fan Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . 30
Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . 31
Ball Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . 31
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fan Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . 32
VM/VP Variable Pitch Key Type Sheaves . . . . . . . . 32
LVP Variable Speed Sheaves . . . . . . . . . . . . . . . . . 33
MVP Variable Speed Sheaves . . . . . . . . . . . . . . . . 34
Fan Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front Load Filter Option . . . . . . . . . . . . . . . . . . . . . 36
Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Winterizing Water Coils . . . . . . . . . . . . . . . . . . . . . . 37
Removing and Replacing Components . . . . . . . . . 37
Removing a Side or Top Panel . . . . . . . . . . . . . . . . 37
Removing a Frame Channel . . . . . . . . . . . . . . . . . . 38
Removing the Fan Section . . . . . . . . . . . . . . . . . . . 38
Removing and Replacing the Coil . . . . . . . . . . . . . . 38
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service and Warranty Procedure . . . . . . . . . . . . . . 41
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Warranty Return Material Procedure . . . . . . . . . . . 41
Check, Test, and Start Procedure Form . . . . . . . . . 42
Quality Assurance Survey Report . . . . . . . . . . . . . 44
2 McQuay IM 672-8
Introduction
CAH 003 G D A C
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 McQua y air ha nd lin g unit
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
General Information
Introduction
Receiving and Handling
VisionTM 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. This equipment
must be installed 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, 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.
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.
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.
Nomenclature
McQuay IM 672-8 3
Introduction
Unit Storage
• Store on a level surface in a clean, dry location where
temperature can be controlled if possible.
• 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.
Belt-Driven fans:
• 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.
• 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
T ensioning‚ page 35.
4 McQuay IM 672-8
Mechanical Installation
4 . 0 0 " b a s e r a i l e x t e n s i o n
W i d t h
3 0 . 0 0 "
4 . 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
3 0 . 0 0 "
H e i g h t
5 4 "
1 2 "
Mechanical Installation
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 removal. 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
devices). Electrical power devices that are mounted on the side
of the unit typically are up to 12" deep (Figure 2). Fan sections
with multiple fans have motor control boxes up to 16" deep
when supplied with VFDs.
Figure 1: Servicing Space Requirements
Figure 2: Service Clearance for Electrical Power Devices
Rigging
Vision 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. When a unit is provided with a
factory-installed base rail, it can be lifted using the 2" diameter
lifting holes located in the corners of each shipping section
(Figure 3). 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 (Figure 4).
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 the
unit.
Figure 3: Units on Base Rails
McQuay IM 672-8 5
Mechanical Installation
R e m o v e
l i f t i n g
b r a c k e t s ( 4 )
I n s t a l l p a n e l s ( 4 )
Figure 4: Units on Skids
Fan sections greater than 108" wide that are stacked on another
section that are not Class II plenum fans are constructed with
internal fan support frames that have integral lifting brackets
(Figure 5). 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.
Class II plenum fans that are stacked on another section may
be lifted using the methods shown in the following figures.
The shipping brackets must remain in place and be tight in
order to lift using this method. Figure 6 shows a belt-drive fan
with field supplied eye bolts that are screwed into factory
installed hex AVK fasteners in the main channels supporting
the fan. Figure 7 shows a direct-drive fan with field supplied
eye bolts on the motor end and straps around the spring
bracket on the inlet end. When factory installed hex AVK
fasteners are installed, they should be used for lifting. When
they are not installed, it is acceptable to lift from the shipping
brackets on the fan. Figure 8 shows dual fans being lifted in a
similar manner as the single direct-drive fan. An eight point
lift must be used for dual fans to make sure both fans are
supported properly and the cabinet structure does not become
overloaded along the center.
If the fan section is connected to another section such as a
plenum or access section, then do NOT attempt to lift both
sections using just the fan section. The other section(s) must
be supported separately using straps.
Figure 6: Belt-Drive Class II Plenum Fan Stacked Unit
Figure 5: Large Fan Sections Stacked on Top of a Lower
Section
Figure 7: Direct-Drive Class II Plenum Fan Stacked Unit
6 McQuay IM 672-8
Mechanical Installation
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 "
S h i m s e c t i o n s u n t i l
t h e y a r e s t r a i g h t
a n d l e v e l
Figure 8: Direct-Drive Class II Dual Plenum Fan Stacked
Unit
Unit Leveling
Place the equipment on a flat and level surface. Where the
surface irregularities could cause the equipment to distort, use
a shim so the base of the unit is 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 (Figure 9).
Figure 9: Leveling the Unit
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. Shipping
sections are 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.
(Figure 19, page 10).
Horizontal Airflow Section Mounting
1 Rig the unit into position and lineup shipping sections in
the direction of air flow. Pull sections together to fasten.
Use a furniture clamp or straps and a ratchet to help pull the
sections together securely (Figure 10).
2 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.
3 If no base rail is provided, fasten the unit in the same
manner on the bottom and top frame channels.
4 Once the sections are positioned together, remove the
fastener in each of the channel corners (on the mating edges
in the channel piece).
5 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.
6 Replace the fasteners in their original position, through the
joining plate.
7 For certain Vision Plus units, use the provided section
joining plates to fasten sections together. Space them as
shown in Figure 11. 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.
McQuay IM 672-8 7
Mechanical Installation
T o p
B o t t o m w i t h b a s e r a i l
R e p l a c e m e n t s c r e w
. 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
A
B
B
A
Figure 10: Horizontal Joining Sections
Figure 11: Frame Channel Stiffener Plates (Vision Plus
Units Only)
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 (Figure 12).
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 (Figure 12).
Figure 12: Vertical/I nv erte d J oin in g Sections
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‚ page 13 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. T o 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.
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 Section Mounting‚ page 7
steps 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 (Figure 13).
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 (Figure 13).
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.
8 McQuay IM 672-8
Mechanical Installation
V i e w A
B o t t o m
w i t h b a s e r a i l
A
T o p
( 2 ) 1 / 4 x 1
D r i l l S c r e w s
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 13: Extended Coil Section Joining
Side-by-Side Heatwheel Section Joining
The side-by-side heatwheel will have two individual sections
parallel in the direction of airflow to be attached to either side.
Each section will attach to the heatwheel section and then to
the other parallel section.
1 Rig the unit into position and line shipping sections up in
direction of air flow. Sections must be pulled together to
fasten using a furniture clamp or straps.
a If the heatwheel section width is greater than 143”, then
rig the section into position using the 2 removable
lifting channels. After section is properly placed,
remove cotter pin and bolts from lifting channel and
discard as seen in Figure 14.
Figure 14: Cotter Pin and Bolt Detail
3 If the unit has a factory installed base rail, fasten the base
rails together using the 3/8”-16 x 5” bolts located in the
splice kit provided with the unit.
a To fasten two shipping sections together, two bolts are
required on the one side. 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.
4 Assemble the center base plates as show in Figure 15,
leaving a 5/16” space between each plate to slide onto
section base channels to center point of section width.
Figure 15: Base Plate Detail
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 the plate spans
the two sections.
7 7 Replace the fasteners in their original position, through
the joining plate.
8 8 Assemble the next section parallel to the assembled
section by following steps 1 – 7 above.
9 9 Using the 3/8”-16 x 1” bolts provided, fasten the two
parallel sections’ bases together as seen in Figure 16.
Figure 16: Base Section Detail
If included, remove center base plates that are attached to
2
the base channels and save for step 4.
McQuay IM 672-8 9
Mechanical Installation
V i e w A
A
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 .
10 Using appropriate safety equipment if necessary, remove
the fastener in each of the channel corners on the top
between the two parallel sections and discard.
11 Use the 2 x 2 holed splice plate with 2 x 5/16”-18 x 1”
screws and 2 x ¼” drill screws. The 2 x 5/16”-18 x 1”
screws will go into the frame channel holes and the 2 x ¼”
drill screws will go into the heatwheel frame channel as
show in Figure 17.
Figure 17: Frame Channel Detail
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 (Figure 19).
Figure 19: Internal Fastening
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‚ page 7.
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 (Figure 20).
For Vision Plus units, ensure that the D-gasket is attached to
Figure 20: Ceiling Suspended with Base Rail
the entering air side frame channel (Figure 18). If it has
dislodged during shipping, restore to original location.
Figure 18: D-Gasket Placement Detail (Vision Plus Units
only)
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 (Figure 21).
10 McQuay IM 672-8
The supporting angle iron must fully support the 2" frame
channel at each section joint.
NOTE
Mechanical Installation
Remove panel
to remove frame
Remove any
panel screws that
engage frame
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 (Figure 22). 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 21: Ceiling Suspended w/o Base Rail—Unitized
Construction
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 (Figure 23).
Figure 23: Removing Panel Screws
Figure 22: Ceiling Suspended w/o Base Rail—Modular
Construction
McQuay IM 672-8 11
Mechanical Installation
Fan Section Doors
Note: Opening fan section doors requires using a 1/2" socket
wrench (Figure 24), which satisfies ANSI standards and
other codes that require the “use of tools” to access
compartments containing moving parts or electrical
wiring.
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.
1
Insert 1/2" socket and rotate 1/4 turn clockwise as shown in
Figure 24. 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 T o prevent air leakage, tighten the door panels by adjusting
the jam nuts.
Figure 24: Opening Fan Section Door
Injected-Foam Insulated Panels
Vision air handlers are furnished with double-wall, injectedfoam 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
(also refer to Figure 25):
a Check that adequate space is available inside the unit
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 that it is airtight, watertight, and
that there is no exposed foam insulation.
WARNING
Flame and smoke can cause eq uipment
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.
12 McQuay IM 672-8
Mechanical Installation
Cut hole from both sides of panel
Seal completely with silicone
sealant or duct seal compound
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.
Figure 25: Cutting/Sealing Injected-Fo a m Insulated panels
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.
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 (Figure 26). 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.
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 requ ire 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 26: Assembly of Fan Coil Sections
Joining
collar
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.
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.
McQuay IM 672-8 13
Mechanical Installation
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 r
J o i n i n g C o l l a r
External Face and Bypass Duct Assembly (Sizes 040 to 090)
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 (also refer to Figure 27).
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
Figure 27: Assembly of Bypass Duct to Unit
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 (Figure 10, page 8).
14 McQuay IM 672-8
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