McQuay OAC 003G Installation Manual

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Installation and Maintenance Manual IM 777-4

Skyline Air Handler

Models OAC/OAH 003G – 090G

Group: Applied Air Systems

Part Number: IM 777

Date: May 2009

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . 3

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . 4

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

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

Curb Mounting and Unit Leveling. . . . . . . . . . . . . 4

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

Shipping Sections . . . . . . . . . . . . . . . . . . . . . . 5

Panels, Frame Channels, and Doors . . . . . . . . . . 7

Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 7

Frame Channel Removal . . . . . . . . . . . . . . . . 7

Access Doors and Panels. . . . . . . . . . . . . . . . 7

Fan Section Doors . . . . . . . . . . . . . . . . . . . . . 7

Injected-Foam Insulated Panels . . . . . . . . . . . 8

Field Mounting Junction Boxes and

Other Components. . . . . . . . . . . . . . . . . . . . . . . . 8

Duct Connections. . . . . . . . . . . . . . . . . . . . . . . . . 8

Dampers and Hoods . . . . . . . . . . . . . . . . . . . . . . 9

Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . 9

Face and Bypass Section Mounting. . . . . . . . . . 10

Piping Vestibules . . . . . . . . . . . . . . . . . . . . . . . . 10

Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . 10

Water Cooling Coils . . . . . . . . . . . . . . . . . . . 10

Direct Expansion Coils . . . . . . . . . . . . . . . . . 10

Steam Coils. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water Heating Coils . . . . . . . . . . . . . . . . . . . 13

Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . 13

Internal Isolation Assembly Adjustment . . . . . . . 14

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . 16

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . 17

Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . 17

Before Starting the Unit: . . . . . . . . . . . . . . . . . . 17

Fan Wheel Alignment . . . . . . . . . . . . . . . . . . 18

Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . 19

Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . 21

Vibration Causes . . . . . . . . . . . . . . . . . . . . . 21

Service and Maintenance . . . . . . . . . . . . . . . . . . . 22

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . 22

Ball Bearing Lubrication. . . . . . . . . . . . . . . . . . . 22

Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . 22

Fan Shaft Bearings. . . . . . . . . . . . . . . . . . . . 22

Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

VM and VP Variable Pitch Key Type Sheaves 23

LVP Variable Speed Sheaves . . . . . . . . . . . 24

MVP Variable Speed Sheaves . . . . . . . . . . . 25

Fan Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . 26

Front Load Filter Option. . . . . . . . . . . . . . . . . . . 28

Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Winterizing Water Coils . . . . . . . . . . . . . . . . 29

Removing and Replacing Components . . . . . . . 29

Removing the Fan Section . . . . . . . . . . . . . . 29

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 31

Service and Warranty Procedure . . . . . . . . . . . . 32

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Warranty Return Material Procedure . . . . . . . . . 32

Check, Test, and Start Procedure Form . . . . . . . 33

Quality Assurance Survey Report. . . . . . . . . . . . 35

Introduction

OAH 003 G D A C

Model

OAH = Outdoor air handler OAC = Outdoor air component

Nominal Unit Size (nominal square foot of coil)

003, 004, 006, 008, 010, 012, 014, 017, 021, 025, 030, 035, 045, 055, 065, 080, 085, 090

Vintage of McQuay Air Handling 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 downstream of belt drive plenum fan F = Motor on inline fan G = Motor downstream of direct drive plenum fan T = Motor behind twin housed fans

Unit Type/Coil Position

B = Blow-thru cooling coil location D = Draw-thru cooling coil location H = Heating only V = Vent only

Introduction

General Information

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 Skyline 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.

Note: Screws, bolts, etc., for assembling sections are supplied

in a bag attached to each section. All necessary gasketing is applied in the factory for section-to-section mounting, unless the unit has a curb ready base. Units require caulk sealant between sections.

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.

Nomenclature

Installation Guidelines

McQuay IM 777-4 3

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

Rigging

In addition to providing adequate space around the unit for piping coils and drains, access to at least one side of the unit is always required to allow for regular service and routine maintenance, which includes filter replacement, drain pan inspection and cleaning, fan bearing lubrication, and belt adjustment. Provide sufficient space—at least equal to the length of the coil—on the side of the unit for coil removal. See

Figure 1 for servicing space requirements.

Maintain at least 54" of clearance in front of electrical power devices. Electrical power devices that are mounted on the side of the unit typically are up to 12" deep (Figure 2).

Figure 1: Servicing Space Requirements

Skyline air assembled, or in modules of assembled sections.

handlers ship as separate sections, completely

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

and the corners of each shipping section.

Units are

provided with a factory-installed base rail

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

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: Unit and Section Rigging

Figure 2: Service Clearance for Electrical Power Devices

Curb Mounting and Unit Leveling

Do not place a Skyline unit over an open curb unless it is equipped with a curb-ready base. Installation instructions for mounting units on a roof curb are provided in IM 770. For a copy, contact your local McQuay representative or visit www.mcquay.com. Make provisions under the unit to divert any moisture from entering the building below.

For units without roof curb mounting, place the equipment on a flat and level surface. Where surface irregularities exist, shim the base of the unit at one or more points along the length of the rails to prevent distortion or sagging of the support rails. Uneven or distorted sections cause misfit or binding of the doors and panels and improper draining of drain pans (Figure 4).

4 McQuay IM 777-4

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

1 / 4 " d i a m e t e r b e a d c e n t e r e d i n f a c e o f c l e a r a n c e

U s e S p l i c e J o i n t a s a g u i d e

R e m o v a b l e L i f t i n g B r a c k e t

Figure 4: Leveling the Unit

Assembling Sections

If the unit is shipped in more than one shipping section, rig each section into position separately. Shipping sections are provided with a connection splice joint attached on the leaving air side of the shipping section that seals against the frame channel on the entering-air side of the adjoining. The splice joint is insulated and provides an air-tight seal between two sections once they are assembled together. Align the splice joint to seat into the mating gasket to provide an air seal. If the splice joint was bent during shipping or rigging, restore it to its original position (Figure 8).

Pull sections together to fasten. Use straps and a ratchet to help pull the sections together securely. Apply sealant to any gaps that may admit moisture.

3 Fasten base rails together first using the 3/8"-16 × 5"

bolts located in the splice kit provided with the unit (Figure 7).

a To fasten two shipping sections together, four bolts

are needed (two on each side of the unit). The bolts are run from one base rail into the other and fastened with a nut. Complete each section bottom and top before attaching additional sections.

b If desired, shipping sections for non curb-ready units

can be fastened together internally. To fasten internally, run field-provided #10 sheet metal screws or drill screws (4" long, maximum) through the interior frame channel of one unit into the splice joint of the neighboring section.

c Handle units with curb-ready bases and vestibules so

the lifting bracket can be removed after the unit is placed on the curbing.

Note: Remove the lifting bracket that projects inward over

the curbing. Save the self tapping screws. When the adjacent section is placed in position, use self tapping screw to secure the bases together.

Figure 6: Remove Vestibule Lifting Bracket

Shipping Sections

Figure 5: Apply Sealant to Mating Faces

McQuay IM 777-4 5

1 Caulk all assembly joints of the unit—Before joining the

sections, apply at least 1/4 inch diameter bead of sealant to the mating faces of the cabinet. Use the splice joint as a guide for applying the sealant (Figure 5).

Mechanical Installation

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 .

5 / 1 6 - 1 8 N u t

S p l i c e P l a t e

5 / 1 6 - 1 8 B o l t

S l i d e S p l i c e C a p o n a n d b e n d e n d s d o w n

Figure 7: Fasten Bottom of Section

“D”

Gasket

3/8" x 1" Bolt and Nut

d A length of “D” gasket is attached to each section

(Figure 7). This gasket MUST be installed to the unit base section.

IMPORTANT

The gasket is to be installed in an arc shape with the ends lower than the center, so that any moisture that may reach the gasket will be drained to the outside of the unit.

e Handle units with curb-ready bases and vestibules so

the lifting bracket can be removed after the unit is placed on the curbing.

Note: Remove the lifting bracket that projects inward over

the curbing. Save the self tapping screws. When the adjacent section is placed in position, use self tapping screw to secure the bases together.

Figure 8: Internal Fastening

1 Check that the sealant is compressed between the mating

channels when the unit sections are joined. Touch up any places where gaps are noted.

2 After sections are seated tightly together, slip the splice

cap over the top panel flanges. Bend the ends of the splice cap down to secure in place (Figure 9).

3 Assemble the small splice plate at the top rail to secure

the sections together at the top. Use 5/16" bolts (Figure 9).

Figure 9: Splice Cap and Splice Plate

6 McQuay IM 777-4

Mechanical Installation

Remove panel to remove frame

Remove any panel screws that engage frame

OPEN

View from inside door

Jam Nuts

Do Not Rotate Cup

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 10).

Figure 10: Removing Panel Screws

that require the “use of tools” to access compartments containing moving parts or electrical wiring. See

Figure 11.

Remove padlock if one is present.

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.

CAUTION

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

ATTENTION

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 11. 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.

Access Doors and Panels

For routine maintenance, access normally is obtained through access doors or by removing side panels. Removing all flat head fasteners along the sides of a panel allow it to be removed.

Fan and filter sections are always provided with a service door on one side of the unit. If requested on order, doors can be provided on both sides of the unit. Optional service doors are available for most section types and are provided based on customer request.

Fan Section Doors

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

wrench, which satisfies ANSI standards and other codes

Figure 11: Opening Fan Section Door

McQuay IM 777-4 7

Mechanical Installation

D i s c h a r g e

P l e n u m

Injected-Foam Insulated Panels

Skyline air handlers now are furnished with double-wall, injected-foam insulated panels. Foam panels are stronger, more rigid, and lighter than panels with fiberglass insulation. The insulation R-value is improved to 13. However, foam insulation can burn when exposed to flame or other ignition sources and release toxic fumes. Take care in cutting and sealing all field-cut openings in these panels.

Panel Cutting Procedure

1 Determine the number and location of holes required for

electrical conduit, piping, and control wiring as follows:

a Check that adequate space is available inside the unit

for conduit or pipe routing.

b Do not locate holes in a panel that provides access to

key maintenance components such as filters and fan assemblies.

c Do not locate where the conduit or piping blocks

airflow or obstructs hinged access doors.

2 Once a proper location is determined, drill a small pilot

hole completely through the panel. Then use a sharp hole saw or a saber saw and cut from each side of the panel.

3 Seal the double-wall panel on each side with an

industrial/commercial grade silicone sealant or duct seal compound. It is extremely important to seal each panel hole or penetration securely so it is airtight, watertight, and so that there is no exposed insulation.

Figure 12: 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 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.

WARNING

Flame and smoke can cause equipment damage, severe personal injury, or death.

Before operating unit, seal all piping and wiring holes on both inner and outer panels with an industrial grade silicone sealant or duct seal compound. Do not use a cutting

torch or expose panel to fire. Panel damage can occur.

WARNING

La fumée et les flammes peuvent endommager le matériel et causesr des blessures graves ou la mort. Avant d’utiliser le dispositif, obturer tous les trous de passage de tubulures et de fils ménagés dans les panneaux intérieurs et extérieurs au moyen d’une pâte à base de silicone ou d’un mastic d’étanchéite â conduits de qualité industrielle. Ne pas se servir d’un chalumeau coupeur ni exposer les pannequx à une flamme nue pour ne pas risquer de les endommager.

The unit frame channel is another excellent location for securing heavier components; self-tapping screws are not acceptable. Ensure that the location permits the full operation of all access doors and panels and does not interfere with other vital components.

Duct Connections

Use flexible connectors on the outlet and inlet duct connections of all units. Do not position down flow fans over air ducts that are routed down into the building. Use a discharge plenum when bottom connections are necessary (Figure 13).

Figure 13: Discharge Plenum

8 McQuay IM 777-4

Mechanical Installation

F l a s h i n g

D u c t

F l a s h i n g

U n i t t o p p a n e l

F l a s h i n g

D u c t

F l a s h i n g

Remove screws and panel to access damper control shaft.

Hood

E x h a u s t

I n t a k e

B a r r i e r

If the unit has a top mixing box or economizer damper or a top duct connection, field fabricate and install flashing to divert moisture from the connection. The flashing must lap over the standing seams of the top panels. The flashing also must lap over the side edges of the unit (Figure 14).

Figure 14: Flashing Over Top Panels and Sides of Units

Dampers and Hoods

Side dampers may be provided in the mixing box and economizer sections of units. When dampers are provided, a removable panel is located above the weather hood to provide access to the damper drive shaft. Other access may be available depending on the specific construction of the unit (Figure 15).

Figure 15: Filler Panel Over the Weather Hood

Figure 16: Field-Installed Barrier Between Hoods

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.

Note: Damper blades are at full flow when open to 70 degrees.

Do not open blades further than 70 degrees.

Fresh air and return air dampers can be linked together and driven from the same actuator if the dampers are the same size. If the dampers are different sizes, they must be driven by separate actuators and controlled appropriately. Exhaust dampers are always driven by a separate actuator.

A typical rotary electric actuator can handle up to 40 sq. ft. of damper. For pneumatic actuators, allow 5 in-lb per square foot of damper area.

CAUTION

Maximum damper rotation is 70°. Maximum shaft torque is 205 inches/pound. Greater rotation or torque can cause equipment damage.

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.

ATTENTION

When units are ordered with exhaust hoods and intake hoods adjacent to each other, install a field-supplied barrier to prevent recirculation of exhaust air into the intake openings. (Figure 16).

McQuay IM 777-4 9

Mechanical Installation

Seal holes cut for piping

Face and Bypass Section Mounting

Internal and external face and bypass sections are mounted together using the instructions for horizontal components and do not require additional instruction. Skyline air handlers are provided with a bypass duct that is integral to the unit construction and requires no field assembly.

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.

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

Piping Vestibules

For units that include a piping vestibule, cut the openings for routing the field piping as required in the field. Carefully seal passages cut through the panels to prevent air leakage. A single metal thickness pan is provided in the bottom of the curb-mounted vestibule. The pan can be removed if necessary. If holes are cut into the pan for a piping passage, seal the holes to prevent moisture leakage (Figure 17).

Figure 17: Seal Holes for Piping—Curb Mounted Units

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

Note: Use glycol in water coils for outdoor air handlers. Power

failures and other mechanical issues can expose coils to freezing temperatures.

• 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.

For units with standard base rails, the vestibule is open to the coil section; therefore, seal all holes to prevent air leakage.

Figure 18: Seal Holes for Piping—Standard Base Rail Units

Direct Expansion Coils

• The coil distributor and suction connection extend through

the end panel of the coil section.

• Check nozzle in distributor for proper tonnage.

• When a (field supplied) thermostatic expansion valve is

located outside the unit and connected directly to the distributor (except on units with piping vestibules). Do not apply heat to the body of the expansion valve.

• 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.

10 McQuay IM 777-4

Mechanical Installation

Steam Coils

Piping (see Figure 19)

• 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

• Pitch all steam coils in units toward the return connection.

• Do not drip supply mains through the coil.

• Do not attempt to lift condensate when using modulating or

on/off control.

• Install vacuum breakers on all applications to prevent retaining condensate in the coil. Generally, connect the vacuum breaker between the coil inlet and the return main. The vacuum breaker should be open to the atmosphere and the trap design should allow venting of large quantities of air.

Traps

Note: Do not place steam traps outdoors.

• Size traps in accordance with the manufacturers’ recommendations. Make sure the required pressure differential is always available. Do not undersize.

• Use float and thermostatic or bucket traps for low pressure steam. On high pressure steam, use bucket traps. Use thermostatic traps only for air venting.

• Use bucket traps for on/off control only.

• Locate traps at least 12 inches below the coil return

connection.

• Multiple coil installation—individually trap each coil or group of coils.

• 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.

• Avoid 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.

McQuay IM 777-4 11

Mechanical Installation

Vacuum breaker 1/2" check valve

Steam main

1/4" petcock for continuous air venting

High pressure float or bucket trap

Return main

1" min.

12" min.

Vacuum breaker 1/2" check valve

Steam main

1/4" petcock for continuous air venting

High pressure bucket trap

Return main

1" min.

12" min.

Full size of return conn.

Vacuum breaker 1/2" check valve

Steam main

Return main

Vacuum breaker 1/2" check valve

Steam main

Return main

12" min.

Vacuum breaker 1/2" check valve

Steam main

Return main

Full size of

Check Valve Strainer Gate Valve

Control valve

modulating

two position

Float and

thermostatic trap

High Pressure (over 25 psi)

Low Pressure (to 25 psi)

5GA or 8GA coils. Note that the

addition of a vacuum breaker to permit the coil to drain during shutdown.

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

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

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

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

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

Figure 19: Piping Arrangements

12 McQuay IM 777-4

12" min.

return conn.

Mechanical Installation

C l e a r a n c e

D r a i n

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‚ page 29.

Figure 20: Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet

Pressure (P)

at the drain pan

Note: The door panels on some applications have a close

clearance over the drain pipes. Extend the drain fitting with a coupling if necessary for door clearance (Figure 21).

Note: Use material that can withstand freezing temperatures

for outdoor drain traps.

Note: Drain traps that dry out can allow cold air to seep into the

equipment.

Figure 21: Extend Drain Fitting for Door Clearance

Drain Pan Traps

Run drain lines and traps full size from the drain pan connection. Install drain pan trap to allow condensate to drain freely. On both blow-through and draw-through units, the trap depth and the distance between the trap outlet and the drain pan outlet must be twice the static pressure in the drain pan section under normal operation so the trap remains sealed (Figure 20).

McQuay IM 777-4 13

Mechanical Installation

Adjusting bolt

Internal Isolation Assembly Adjustment

On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment. with a tie-down at each point of isolation.

Before Operating the Unit:

Remove the shipping brackets and tie-down bolts (see

Figure 23 and Figure 24) and discard. The shipping brackets

located on the opposite drive side of the unit are difficult to access from the drive side of the unit. Either remove them before the unit is assembled or remove the panel on the opposite drive side to gain access.

The spring isolators under the four corners of the fan and motor assembly are factory adjusted while the fan was not running. See Table 1 and Ta ble 2 below. With the unit operating at normal cfm and static pressure, all the isolators should be at the same height opening. If adjustments are required, loosen the 1/2" cap screw on top of the isolator and turn the adjusting bolt to lower or raise the fan and motor base. Retighten the cap screw when adjustments are completed.

Table 1: Motor Beside Fan Spring Mount Adjustments

Spring mount adjustment at rest

Fan discharge

position

13.753.754.25

24.253.754.25

34.253.754.25

43.753.754.25

16.006.756.75

26.506.756.75

36.506.756.75

46.006.756.75

Top or bottom

horz. H

Unit sizes 003 – 035

Unit sizes 040 – 090

Downblast

Upblast

Table 2: Motor Behind Fan Spring Mount Adjustments

Spring mount adjustment at rest

Fan discharge

position

1 6.75 6.75 6.75 2 6.75 6.75 6.75 3 6.75 6.75 6.75 4 6.75 6.75 6.75

Top or bottom

horz. H

Unit sizes 003 – 035

Unit sizes 040 – 090

Downblast

Upblast

For models 040 through 090, the isolators should be at equal For models 040 through 090, the isolators should be at equal height during fan operation (6"). Center the fan outlet in the outlet panel opening. If adjustment is required, loosen the cap screw on top of the isolator assembly. Turn the adjustment nut below the fan frame to lower or raise the fan motor and frame assembly. Retighten the cap screw on top of the isolator assembly.

Figure 22: Adjusting Large Spring Mount Assembly

14 McQuay IM 777-4

Figure 23: Removing “Motor Behind” Shipping Brackets Figure 24: Removing “Motor Beside” Shipping Brackets

Unit sizes 006 - 090

M o t o r

F a n

P O S 1

P O S 2

P O S 3

P O S 4

A i r f l o w

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

D i m " H "

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 h o l d

d o w n s c r e w

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

D e t a i l A

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

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

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

Unit sizes 006 - 090

Mechanical Installation

McQuay IM 777-4 15

Electrical Installation

Conduit Entrance (typical)

Fan Motor Junction Box

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, 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.

Figure 25: Electrical Conduit Location

CAUTION

The base section of each cabinet has a drip pan installed below every panel that drains to the outside frame trough. Any holes cut through the bottom of the unit must also penetrate the drip pan. If holes are cut in the drip pan, seal them to prevent moisture leakage.

ATTENTION

CAUTION

Use copper conductors only. Failure to use copper

conductors can result in equipment damage.

ATTENTION

Utiliser du fil de cuivre seulement. La non utilisation de fil de cuivre peut causer des dommages à l’équipement.

• Electrical service to the fan must correspond to the rated voltage on the motor or electrical panel nameplate and conform to the National Electric Code and local restrictions.

• Connect the fan section metal frame to the building electrical ground.

• A door electrical interlock is not provided as standard.

• Thermal motor protection is external to the unit.

Locate electrical conduit entrances for units above the bottom of the unit, high enough to clear components inside, but below the bottom of the fan motor junction box (Figure 25).

Chaque cabinet est muni d’une base avec une panne d’égouttement installée en-dessous de chaque panneau qui évacuera l’eau vers la gouttière extérieure. Tous les trous percés au bas de l’unité doivent pénétrer la panne d’égouttement. S’il y a des trous dans la panne d’égouttement, les sceller pour empêcher les fuites d’eau.

• When the unit is provided with an external junction box and variable frequency drive (VFD), the VFD itself will be mounted on the drive side fan panel inside the fan cabinet. The external junction box will provide loose wire connection to the VFD and to the motor. An external mounted keypad/display control box will be provided and connected to the VFD for manual adjustment of the VFD.

• When not being serviced, close and secure electrical panel doors to prevent accidental contact with live parts and prevent ingress of moisture and airborne contaminants.

• Control wiring—access to the VFD is through the fan cabinet access door. Provide shielded cable only as described in the VFD manual provided with the unit. Route wire through panel so that it not interfere with any other components or in the way of any access doors. Do not drill through drip or drain pans. Refer to the VFD installation manual provided with the unit for detailed control wiring instructions.

16 McQuay IM 777-4

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.

Operation Guidelines

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 Check that ball bearings on the fan shaft and motor are

prelubricated and do not need grease before startup.

6 Check tightness of setscrews in bearings and fan

wheel(s). If retightening is needed, position the fan wheel(s) per Table 3 or Table 4, page 18. Torque set

screws per Table 7, page 19.

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.

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

Adjust if necessary. Check tightness of sheave setscrews and/or capscrews. See Table 7, page 19.

2 Leak test the thermal system to verify that connections are

tight.

3 Check that the condensate drain is trapped.

4 Rotate the shaft by hand to be sure it is free.

Fan Startup:

Start and run fan. Observe the rotation. If the fan operates backward, reverse two legs of the three-phase motor connections.

McQuay IM 777-4 17

Operation Guidelines

E q u a l s p a c i n g a l l a r o u n d

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

Overlap

Note: Variable pitch fan drives usually are provided for

operation in the mid-speed adjustment range. However, the drives usually ship with the adjustment opened up for minimum fan speed. Adjust the drives for the proper airflow. See Fan Drive‚ page 23.

After the First 48 Hours of Operation:

Disconnect and lock electrical power source.

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

(or capscrews). See Table 7, page 19.

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 26: Wheel-to-Inlet Tunnel Relationship—Airfoil Type Fan Wheels (Housed)

Table 4: 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

Note: 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 28: Wheel-to-Inlet Funnel Relationship—Plenum Fans

Table 3: 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

Note: 1. To obtain rated air performance, dimensional relationship must be

held.

2. To obtain dimension A, loosen setscrews in wheel hub(s), shifting wheel(s) axially as needed, and retightening setscrews.

3. To obtain dimension B, loosen screw and washer fasteners around periphery of funnel(s), shifting funnel radially as required, and retorquing fasteners.

Dia.

36.50 12.78 325 0.38 9.65

40.25 14.31 363 0.50 12.70

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

Figure 27: Wheel-to-Inlet Funnel Relationship—Forward Curved Type Fan Wheels

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

Wheel—funnel overlap

Size Overlap

13.5 .25 15 .31

16.5 .38

18.25 .44 20 .50

22.25 .56

24.5 .62 27 .69 30 .75 33 .81

36.5 .88

40.25 1.00

44.5 1.12 49 1.25

54.25 1.38 60 1.50

18 McQuay IM 777-4

Operation Guidelines

Overlap

300 250

200 150

100

90 80 70

60 50

750

800

850

900

1000

1500

2000

Fan speed (rpm)

40 35

AF24.00

AF21.56

AF19.69

AF16.19

AF14.56

AF13.22

2500

3000

3500

4000

4500

350

400

450

Torque (in–lb)

Figure 29: Wheel-to-Inlet Funnel Relationship—Inline Fans

Table 6: 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

Table 6: Wheel-to-Inlet Funnel Relationship—Inline Fans

330 1.000 365 1.125 402 1.250 445 1.375

Table 7: 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

Operating Limits

Do not exceed the operating limits in Tab le 8. 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 8: 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 2700 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 30: Torque for FC Variable Inlet Vanes (in–lb) Figure 31: 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

FC36.00

FC33.00

500

450

550

400

Fan speed (rpm)

FC30.25

FC27.62

600

650

700

FC25.00

FC22.38

750

850

800

900

1000

FC20.00

1500

McQuay IM 777-4 19

Operation Guidelines

300 250

200

150

100

80 70

60 50

350

400

450

500

550

600

650

700

750

800

850

900

1000

1500

2000

Fan speed (rpm)

FC22.25

FC20.00

FC18.00

FC15.00

FC12.62

FC24.50

Torque (in–lb)

300 250

200 150

100

600

650

700

750

800

850

1000

Fan speed (rpm)

900

400 350

550

900

AF40.25

AF27.00

AF24.50

AF22.25

AF20.00

AF38.50

AF33.00

AF30.00

500

600

700

800

2000

1000

1500

2000

3000

2500

Torque (in–lb)

Table 9: Unit Sizes 040 to 090

Fan operating limits

Forward curved—housed Diameter 20 22.38 25 27.62 30.25 33 36 Maximum rpm Class I 1010 930 790 690 650 600 560 Maximum rpm Class Il 1281 1178 1011 910 835 763 715 Airfoil—housed Diameter 20 22.25 24.5 27 30 33 36.5 Maximum rpm Class I 2077 1875 1691 1479 1328 1209 1073 Maximum rpm Class Il 2703 2413 2199 1928 1730 1579 1401

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

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

Table 10: 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

Table 11: 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

20 McQuay IM 777-4

Operation Guidelines

700

600

500

400

100

900

300

200

Torque (lb./in.)

Fan Speed (rpm)

800

900

1000

1500

2000

400

500

600

700

300

200

3000

800

1000

2000

3000

4000

5000

Torque (in-lb)

Figure 34: Torque Requirements at 100% WOV for SWSI Plenum Fans with NESTED Inlet Vane

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 Tab le 1 2.

Table 12: 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.

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 777-4 21

Service and Maintenance

Periodic 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

CAUTION

Bearing overheating potential. Can damage the equipment. Do not overlubricate bearings. Use only a high grade mineral grease with a 200°F safe operating temperature. See below for specific recommended lubricants.

Motor Bearings

Supply and return fans—Supply and return fan motors should have grease added after every 2000 hours of operation. Using the following procedure, relubricate the bearings while the motor is warm, but not running. Use one of the greases

shown in Table 13.

Table 13: Recommended Lubricants and Amounts for Fan Motor Bearings

Mfr. Grease NEMA Size

56 to 140

Texaco, Polystar

Polyrex EM (Exxon Mobile)

Rykon Premium #2

Penzoil Pen 2 Lube

140 180 210 250 0.47 280 0.61 320 0.76 360 0.81 400 1.25 440 2.12

1 Remove and clean upper and lower grease plugs.

2 Insert a grease fitting into the upper hole and add clean

grease (Table 13) with a low pressure gun.

3 Run the motor for five minutes before replacing the

plugs.

Note: Specific greasing instructions are located on a tag

attached to the motor. If special lubrication instructions are on the motor, they supersede all other instructions.

Fan Shaft Bearings

Any good quality lithium or lithium complex base grease, using mineral oil, conforming to NLGI grade 2 consistency, and an oil viscosity of 455-1135 SUS at 100°F (100-200 cSt at 40°C) may be used for relubrication.

Amount to Add

(oz.)

0.08

0.15

0.19

0.30

Compatibility of grease is critical. Relubricatable bearings are supplied with grease fittings or zerks for ease of lubrication with hand or automatic grease guns. Always wipe the fitting and grease nozzle clean.

CAUTION

For safety, stop rotating equipment. Add one half of the recommended amount shown in Figure 16. Start bearing, and run for a few minutes. Stop bearing and add the second half of the recommended amount. A temperature rise, sometimes 30°F (1°C), after relubrication is normal. Bearing should operate at temperature less than 200°F (94°C) and should not exceed 225°F (107°C) for intermittent operation. For a relubrication schedule, see Table 14. For applications that are not in the ranges of the table, contact McQuay.

CAUTION

The tables below state general lubrication recommendations based on our experience and are intended as suggested or starting points only. For best results, specific applications should be monitored regularly and lubrication intervals and amounts adjusted accordingly.

Table 14: Relubrication Intervals

(Use NLGI #2 Lithium or Lithium Complex Grease)

Speed Temperature Cleanliness Relub. intervals

100 rpm

500 rpm

1000 rpm

1500 rpm

Above 1500 rpm

Max catalog rating

Table 15: Recommended Lubricants for Fan Shaft Ball Bearings

Name Temperature Base Thickener

Texaco, Premium RB Mobile, AW2

Mobile, SHC

100

Chevron,

Altiplex

Synthetic

Exxon, ronex MP40°

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

temperature applications are not suitable for standard air handler components.

Up to

120°F

(50°C)

Up to

150°F

(65°C)

Up to

210°F

(100°C)

210°F

Over

(100°C) to

250°F (120°C)

Up to

150°F

(65°C)

150°F

Over

(65°C) to 250°F

(120°C)

Above

250°F

(120°C)

30°

350°F

(34° to 177°C)

40°

437°F

(40° to 175°C)

68°

356°F

(50° to 180°C)

60°

450°F

(51° to 232°C)

300°F

(40° to 149°C)

Clean 6 to 12 months

Clean 2 to 6 months

Clean

Clean Weekly

Dirty/wet 1 week to 1 month

Dirty/wet Daily to 2 weeks

Parafinic mineral oil Mineral oil Lithium 2

Synthetic Lithium 2

Mineral oil Lithium 2

2 weeks to 2

months

Contact Browning

NLGI

grade

Lithium 2

22 McQuay IM 777-4

Table 16: Recommended Fan Relubrication Grease Charge

Shaft Size (in) OZ. Shaft Size Grams

1/2 to 3/4 0.03 20 mm 0.85

7/8 to 1-3/16 0.10 25-30 mm 2.84

1-1/4 to 1-1/2 0.15 35-40 mm 4.25

1-11/16 to 1-15/16 0.20 45-50 mm 5.67

2 to 2-7/16 0.30 55-60 mm 8.51

2-1/2 to 2-15/16 0.50 65-70 mm 15.59

3 to 3-7/16 0.85 75-80 mm 24.10

3-1/2 to 4 1.50 85-105 mm 42.53

Fan Drive

WARNING

Before servicing fans, lock out and tag out all power to the unit. Fans or belts can cause severe personal injury or death.

AVERTISSEMENT

Avant de faire le service sur les ventilateurs,couper et indiquer que le courant est coupé. Les ventilateurs ou les

courroies peuvent causer des blessures personnelles graves ou entraîner la mort.

WARNING

Do not open the hinged access door and screw-fastened access panels while the unit is operating. Moving parts and

strong suction forces can cause severe personal injury or death.

AVERTISSEMENT

Ne pas ouvrir les portes d’accès à charnières et les panneaux à vis lorsque l’unité fonctionne. Les pièces

mobiles et le niveau de succion peuvent causer des blessures personnelles graves ou même entraîner la mort.

Service and Maintenance

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

Adjusting

1 Loosen setscrews B and C in moving parts of sheave and

pull out external key 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 six full turns for

3 Replace external key E and securely tighten setscrews B

over key and setscrews sheave.

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

over grooves. See Fan Drive Belt‚ page 26.

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 35: VP Type Sheave Adjustment

A securely in place.

E. (This key projects a small

B belts.

C into keyway in fixed half of the

A belts or

Upon completion of the air balance, replace the variable

pitched motor sheave with a properly sized, fixed sheave. A matching fixed sheave provides longer belt and bearing life and minimizes vibration. Initially, it is best to have a variable pitched motor sheave for the purpose of air balancing. Once the balance is achieved, fixed sheaves maintain balancing and alignment more effectively. Replace the adjustable sheaves with fixed sheaves.

With the electrical power disconnected, locked and tagged out, measure the diameter of the V-belt outer surface where it

Single Groove

Key E projects to provide a grip for removal.

Do not operate

sheeves with flange projecting beyond the hub end.

passes around the sheave (pitch diameter). Calculate fan speed from the motor nameplate rpm.

Fan rpm = motor rpm ×

Measured diameter at motor sheave Measured diameter at fan sheave

VM and VP Variable Pitch Key Type Sheaves

Two Groove

Mounting

1 Mount all sheaves on the motor or driving shaft with the

setscrews

McQuay IM 777-4 23

A toward the motor.

Service and Maintenance

Section A-A Section A-A

LVP Variable Speed Sheaves

Mounting

1 Slide sheave on motor shaft so that the side of the sheave

with setscrew 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 twogroove 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

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.

A is next to the motor when setscrew A is

A securely.

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

over grooves. See Fan Drive Belt‚ page 26.

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.

6 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 belts or six turns for

7 Replace key F.

8 Tighten setscrews D and capscrews E.

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

B belts.

have not been installed, install them and adjust belt tension. Do not force belts over grooves. See Fan Drive

Belt‚ page 26.

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 operation.

Figure 36: LVP Type Sheave Adjustment

24 McQuay IM 777-4

Service and Maintenance

MVP Variable Speed Sheaves

into the three holes that are located 120° apart on the ring.

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 37, page 26.

2 Verify that all setscrews are torqued to the values shown

in Figure 17, page 25 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

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:

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

belts or 6 turns for the B belts.

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

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

d Do not open 8V sheaves more than 8 turns.

6 Tighten BOTH locking screws A in the outer locking

ring before operating the drive. Use a torque wrench and tighten to the value shown in Table 1 7.

7 Replace belts and adjust the motor base to tension the

belts properly. See Fan Drive Belt‚ page 26.

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 17: 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

McQuay IM 777-4 25

Service and Maintenance

Motor

Must be parallel

Adjustable Sheave

Center lines must coincide

Bearing

Must be parallel

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

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

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

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

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

O u t e r

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

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

Figure 37: Sheave Adjustment

Figure 38: Sheave Adjustment

Fan Drive Belt

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 39, page 27.

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 Belt Deflection Force

(per Browning® specifications)‚ page 27.

26 McQuay IM 777-4

Figure 39: Drive Belt Adjustment

Deflection =

Belt span

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.

Service and Maintenance

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.

Table 18: 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 -1 6.0

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

McQuay IM 777-4 27

Service and Maintenance

F i l t e r F r a m e

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

P r e f i l t e r

F i n a l F i l t e r

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 (Figure 40).

Figure 40: Frame and Filters with Holding Clips

Filter Gauges

Filter gauges indicate pressure drop for installed filters.

Table 19 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 41: Filter Gauge

Table 19: 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

Coils

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.

28 McQuay IM 777-4

Service and Maintenance

3 Dirt and lint can clog the condensate drain, especially

with dirty filters. Inspect twice a year to help avoid overflow.

Winterizing Water Coils

Coils can freeze due to air stratification or failure of outdoor air dampers and/or preheat controls. Do not depend on routine draining of water cooling coils for winter shutdown as insurance against freeze-up. Severe coil damage can result. Drain all coils as thoroughly as possible and then treat in the following manner.

• Fill each coil independently with an antifreeze solution using a small circulating pump and again thoroughly drain.

• Check freezing point of antifreeze before proceeding to next coil. Due to a small amount of water always remaining in each coil, there is a diluting effect. The small amount of antifreeze solution remaining in the coil must always be concentrated enough to prevent freeze-up.

Note: Carefully read instructions for mixing antifreeze solution

used. Some products have a higher freezing point in their natural state when mixed with water. McQuay

International is not responsible for the freezing of coils.

WARNING

Mold can cause personal injury. Clean drain pan regularly so

mold does not develop.

AVERTISSEMENT

La moisissure présente un danger respiratoire. Pour éviter

la moisissure, nettoyer régulièrement le bassin de drainage.

Removing and Replacing Components

See Access Doors and Panels‚ page 7 for instructions on removing panels and opening fan access doors to remove or replace components.

WARNING

Before removing any component, lock out and tag out all power to the unit. Fans and belts can cause severe personal

injury or death.

AVERTISSEMENT

Avant d’enlever toute composante, couper et indiquer que l’alimentation électrique à l’unité est coupée. Les

ventilateurs et les courroies peuvent entraîner des blessures personelles graves ou même la mort.

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

1 Remove the side panels and any intermediate supports

(follow instructions for side panel removal).

2 Once the panels and any intermediate supports are

removed, disconnect the neoprene bulk head seal that is attached to the fan discharge.

3 Remove the four discharge angles that hold the neoprene

canvas in place around the discharge opening.

4 Disconnect the fan sled from each of the corner mounts

and pull the entire assembly out the side of the unit.

5 After the fan sled is out, loosen the fan bearings and pull

out the shaft.

6 Disconnect the fan housing from the fan sled, and

bearing support by removing the attaching bolts.

7 Replace the new fan, reconnect the shaft and bearings

and put the fan assembly in the cabinet.

8 Replace panels and fasteners.

Removing and Replacing the Coil

Removing Single Coils

Note: Single coils are bolted to the unit on the connection end.

The connection end is held in place with a clamp.

Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.

2 Remove all screws and remove the access panel.

3 Remove the screws holding the coil in place.

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 Single Coil Top

Installation/Removal‚ page 30.

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

4 Caulk the seams between the coil casings and bulkheads.

5 If this is an additional coil being installed and not a

replacement, locate the coil supply and return connections dimensionally. Carefully drill holes in the end panels of the unit.

6 Remove the brass plugs for the vents and drains on the

connections.

7 Slip the panel over the connections.

8 Replace the brass plugs and panel fasteners.

McQuay IM 777-4 29

Service and Maintenance

Coil

Connection

end

Coil

Opposite

connection

end

Coil

Connection end

Coil

Opposite connection end

Coil Bulkhead

Coil Rests

Figure 42: Single Coil Top Installation/Removal

Figure 43: Single Coil Side Installation/Removal

Removing Stacked Coils

Note: Top and bottom stacked coils are held together with steel

plate and screws on one side and drain trough and screws on the other side. Remove the plate and trough before removing the coils. The coils cannot be removed attached together.

1 Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.

2 Remove all screws and remove the access panel.

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.

30 McQuay IM 777-4

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.

Parts

Replacement Parts

When writing to McQuay for service or replacement parts, refer to the model number and serial number of the unit stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

Parts

McQuay IM 777-4 31

Service and Warranty Procedure

Service and Warranty Proc edure

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. Therefor, a purchase order must be entered through the nearest McQuay representative. The order should include part number, model number, and serial number of the unit involved.

Credit will be issued on customer's purchase order following an inspection of the return part and upon determination that the failure is due to faulty material or workmanship during the warranty period.

32 McQuay IM 777-4

Check, Test, and Start Procedure Form

To comply with the terms of McQuay Warranty, complete and return this form within 10 days to McQuay Warranty Department.

Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery.

Job Name:________________________________________

Installation address: __________________________________________________________________________________________________

City: ______________________________________________________________________________ State: __________________________

Purchasing contractor:________________________________________________________________________________________________

City: ______________________________________________________________________________ State: __________________________

Name of Person doing start-up (print) ___________________________________________________________________________________

Company name _____________________________________________________________________________________

Address ___________________________________________________________________________________________

City/State/Zip_______________________________________________________________________________________

Unit model number: ________________________________________________ Unit serial number: _______________________________

SF VFD model number:_____________________________ Serial number: ___________________________________ RF VFD model number:_____________________________ N/A

Circle Yes or No. If not applicable to the type of unit, circle N/A.

I. INITIAL CHECK

A. Is any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

B. Are fan drives properly aligned and belts properly adjusted? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

C. Tightened all setscrews on pulleys, bearings and fans? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

D. Have the hold-down bolts been backed off on spring mounted fan isolators? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

E. With power off, do fans turn freely by hand? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

F. Electrical service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ye s No N/A

Volts __________ Hertz __________ Phase __________

G. Is the main disconnect adequately fused and are fuses installed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

H. Are all electrical power connections tight? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

I. Is the condensate drain trapped?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

J. Fill drain pan. Does water drain freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

K. Is the unit mounted level? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

II. FAN DATA

A. Check rotation of supply fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

B. Voltage at supply fan motor: 1–2 _________ V 2–3__________V 1–3 _________ V C. Supply fan motor amp draw per phase: L1____________ L2 ___________ L3 ___________ D. Overload amp setting: ______________

E. What is the supply fan rpm? ______________

F. Check rotation of return fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

G. Voltage at return fan motor: 1–2 _________ V 2–3__________V 1–3 _________ V H. Return fan motor amp draw per phase: L1____________ L2 ___________ L3 ___________

I. Overload amp setting: ______________

J. What is the return fan rpm? ______________

K. Record supply static pressure at unit discharge: _______ inches of H20

L. Record return static pressure at unit (with outside air dampers closed) _____________ inches of H20

III. DAMPERS

A. Are blades and seals present?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

B. Do dampers open smoothly and shut tight?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

IV. ELECTRIC HEAT

A. Electrical heat service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

_________ Volts _________Hertz _________Phase

B. Are there any signs of physical damage to the electric heat coils? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

C. Have all electrical terminals been tightened?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

D. Does sequence controller stage contactors properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

E. Electric heater voltage across each phase: L1–2_________V L2–3________ V L1–3 _______ V

F. Amp draw across each phase at each heating stage:

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6

Phase L1: ___________ ___________ ____________ ____________ ___________ ___________

McQuay S.O. No.: _________________ McQuay G.O. No.: _________________

N/A

Serial number: ___________________________________

McQuay IM 777-4 33

Check, Test, and Start Procedure Form

Phase L2: ___________ ___________ ____________ ____________ ___________ ___________

Phase L3 ___________ ___________ ____________ ____________ ___________ ___________ G. FL A: L1 ___________ L2 ___________ L3____________

H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control.. . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

V. CHILLED WATER COIL

A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

B. Drain pan draining okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

VI. HOT WATER COIL

A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

VII. HEAT RECOVERY

A. Heat wheel rotates freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

B. Heat wheel VFD operates properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

C. Heat wheel VFD model #_____________________ serial #:_____________________ . . . . . . . . . . . . . . . . . . . . . . . N/A

D. Check for air bypass around heat wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

Yes No N/A Yes No N/A

Signature: ______________________________________________________ Startup date:____________________________________

RETURN COMPLETED FORM WITHIN 10 DAYS OF START-UP TO: McQuay International Warranty Department, 13600 Industrial Park Boulevard, Minneapolis, MN 55441

Please list any additional comments that could affect the operation of this unit; e.g., shipping damage, failed components, adverse installation applications, etc., on a separate sheet and attach to this form.

34 McQuay IM 777-4

Quality Assurance Survey Report

To whom it may concern: Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the

product. Job Name: _____________________________________________________ McQuay G.O. no. __________________ Installation Address: _____________________________________________________ City: __________________________________________________________ State: __________________ Purchasing Contractor: __________________________________________________ City:__________________________________________________________

Name of person doing start-up (print): _____________________________________________________

1. Is there any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

__Location on unit _____________________________________________________

2. How would you rate the overall appearance of the product; i.e., paint, fin damage, etc.? Excellent Good Fair Poor

3. Did all sections of the unit fit together properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

4. Did the cabinet have any air leakage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location on unit ___________________________________________________________________________

5. Were there any refrigerant leaks? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

Shipping Workmanship Design

6. Does the refrigerant piping have excessive vibration?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location on unit ___________________________________________________________________________

7. Did all of the electrical controls function at start-up? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments _______________________________________________________________________________

8. Did the labeling and schematics provide adequate information? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A

9. How would you rate the serviceability of the product? Excellent Good Fair Poor

10. How would you rate the overall quality of the product? Excellent Good Fair Poor

11. How does the quality of McQuay products rank in relation to competitive products? Excellent Good Fair Poor

Comments: Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed

components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty Department with the completed preceding “Equipment Warranty Registration Form”.

State: __________________

Yes No N/A

McQuay IM 777-4 35

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.

McQuay OAC 003G Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

General Information

Receiving and Handling

Unit Storage

Nomenclature

Installation Guidelines

Mechanical Installation

Service Clearances

Rigging

Curb Mounting and Unit Leveling

Assembling Sections

Shipping Sections

Panels, Frame Channels, and Doors

Panel Removal

Frame Channel Removal

Access Doors and Panels

Fan Section Doors

Injected-Foam Insulated Panels

Field Mounting Junction Boxes and Other Components

Duct Connections

Dampers and Hoods

Mounting Actuators

Face and Bypass Section Mounting

Piping Vestibules

Piping and Coils

Water Cooling Coils

Direct Expansion Coils

Steam Coils

Water Heating Coils

Drain Pan Traps

Internal Isolation Assembly Adjustment

Electrical Installation

Wiring

Operation Guidelines

Startup Checks

Before Starting the Unit:

Fan Wheel Alignment

Operating Limits

Fan Vibration Levels

Vibration Causes

Service and Maintenance

Periodic Maintenance

Ball Bearing Lubrication

Motor Bearings

Fan Shaft Bearings

Fan Drive

VM and VP Variable Pitch Key Type Sheaves

LVP Variable Speed Sheaves

MVP Variable Speed Sheaves

Fan Drive Belt

Front Load Filter Option

Filter Gauges

Coils

Winterizing Water Coils

Removing and Replacing Components

Removing the Fan Section

Parts

Replacement Parts

Service and Warranty Procedure

Warranty

Warranty Return Material Procedure

Check, Test, and Start Procedure Form

Quality Assurance Survey Report