McQuay RE090ACYQY Installation Manual
Installation and Maintenance Manual IM-806
Group: Light Commercial
Part Number: IM-806
Date: August 2005
Supersedes: March 2005
RG and RE Combination Heating and Cooling
Outdoor Units
7-1/2 and 10 tons
.
© 2004 McQuay International
IM-806 Page 1
Table of Contents
MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Codes and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Message to the Installer . . . . . . . . . . . . . . . . . . . . 4
Important Message to the Owner . . . . . . . . . . . . . . . . . . . . . 4
Recognize Safety Symbols, Words, and Labels . . . . . . . . . . 4
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS HEAT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROOF CURB ASSEMBLY & INSTALLATION . . . . . . . . . . 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cantilever Curb: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Full Perimeter Curb: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VERTICAL DISCHARGE DUCT CONNECTIONS . . . . . . . 10
DUCT INSTALLATION BEFORE UNIT PLACEMENT . . . . 10
DUCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DUCT INSTALLATION AFTER UNIT PLACEMENT . . . . . 12
HANDLING AND RIGGING . . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RIGGING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
UNIT INSTALLATION ON ROOF CURB . . . . . . . . . . . . . . 13
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CURB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PROTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HORIZONTAL DISCHARGE DUCT CONNECTIONS . . . . 13
ACCESSORY OUTSIDE AIR OPTIONS - FIELD
INSTALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 14
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ELECTRICAL ENTRANCE LOCATIONS . . . . . . . . . . . . . . 14
MAIN POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOW VOLTAGE CONTROL WiRING . . . . . . . . . . . . . . . . . 15
GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LOCATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . 16
CONDENSATE DRAIN CONNECTION . . . . . . . . . . . . . . . 17
EXTERIOR WIND SHIELD INSTALLATION . . . . . . . . . . . 17
CHECK, TEST AND START PROCEDURES . . . . . . . . . . 18
BEFORE STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TOOLS REQUIRED TO PERFORM CHECK,
TEST & START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TEMPORARY HEATING OR COOLING . . . . . . . . . . . . . . 18
CONTRACTOR RESPONSIBILITY . . . . . . . . . . . . . . . . . . 18
PRELIMINARY IN BUILDING . . . . . . . . . . . . . . . . . . . . . . .18
CHECK OF ROOF CURB INSTALLATION . . . . . . . . . . . . 18
CHECK FOR MINIMUM CLEARANCES . . . . . . . . . . . . . . .18
CHECK AND REPORT DAMAGE . . . . . . . . . . . . . . . . . . . .18
CHECK FOR OBSTRUCTIONS, FAN CLEARANCE AND
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PRE-STARTUP PRECAUTIONS . . . . . . . . . . . . . . . . . . . .19
CHECK FIELD DUCT CONNECTIONS . . . . . . . . . . . . . . .19
CONTROL SYSTEM CHECK, TEST & START
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CONTROL VOLTAGE CHECK . . . . . . . . . . . . . . . . . . . . . .19
THERMOSTAT PRELIMINARY CHECK . . . . . . . . . . . . . . 19
ECONOMIZER DAMPERS & FILTERS CHECK, TEST &
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
FILTER SECTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . .19
EVAPORATOR BLOWER FAN CHECK, TEST & START
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ECONOMIZER & DAMPER SECTION CHECK . . . . . . . . .20
BEARING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SET EVAPORATOR FAN RPM . . . . . . . . . . . . . . . . . . . . .20
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TENSION AND ALIGNMENT ADJUSTMENT . . . . . . . . . . .21
EVAPORATOR FAN ROTATION CHECK . . . . . . . . . . . . . 21
ELECTRICAL INPUT CHECK . . . . . . . . . . . . . . . . . . . . . . .21
RESTORING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . .21
REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 22
CHECK, TEST & START PROCEDURE PRELIMINARY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
REFRIGERATION SEQUENCE CHECK . . . . . . . . . . . . . .22
REFRIGERATION PERFORMANCE CHECK . . . . . . . . . .23
GAS HEAT CHECK, TEST & START PROCEDURE . . . .23
GAS SUPPLY PRESSURES & REGULATOR
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SEQUENCE OF OPERATION - GAS HEATING . . . . . . . .24
LS Automatic Reset High Limit Control . . . . . . . . . . . . . . . .24
ALS Automatic Reset High Limit Control . . . . . . . . . . . . . . 24
RS Manual Reset Flame Rollout Control . . . . . . . . . . . . . .24
INPUT RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
AIR BALANCING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DRIVE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MOUNTING & ADJUSTING MOTOR SHEAVES VL, VM &
2VP VARIABLE PITCH KEY TYPE SHEAVES
MOUNTING: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ADJUSTING VL & VM SHEAVES: . . . . . . . . . . . . . . . . . . .25
AFTER ADJUSTING: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
VENTOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
INSPECTION & CLEANING . . . . . . . . . . . . . . . . . . . . . . . .26
© 2004 McQuay International, Minneapolis MN. All rights reserved throughout the world.
McQuay International reserves the right to change any information contained herein without prior notice. The user is responsible
for determining whether this product is appropriate for his or her application.
Manufactured by Goodman Manufacturing Co., L. P., Houston, TX 77008
Page 2 IM-806
MODEL NOMENCLATURE
M
R
R
N
0
1
E
C
V
le
odel
G = Rooftop Gas
E = Rooftop Electric
ominal Capacity (tons)
90
20
intage
ER
= 10
Table 1: Unit Nameplate Model Number Identifier
Unit Nameplate McQuay Model Number
PCC090-3A RE090ACYPY
PCC090-4A RE090ACYQY
PCC120-3A RE120ACYPY
PCC120-4A RE120ACYQY
PGC090195-3A RG090ACFPY
PGC090195-4A RG090ACFQY
PGC120225-3A RG120ACGPY
PGC120225-4A RG120ACGQY
RG
090
A
FPY
C
Future Use
Voltage/Phase
P = 208-230/3/60
Q = 460/3/60
Heating Input
(BTUH)
F = 195,000
G = 225,000
Y = Not Applicab
IM-806 Page 3
INTRODUCTION
General Description
These installation instructions cover the outdoor installation of
single package gas-electric heating and cooling units. See the
product catalog applicable to your model for information
regarding specifications applicable to your model and accesso
ries.
Receiving Inspection
McQuay products are carefully inspected prior to shipment
and the carrier has assumed responsibility for loss or damage
upon acceptance of the shipment.
Upon receiving your shipment, check all items carefully
against the Bill of Lading. Inspect the unit and/or accessories
for shipping damage as soon as they are received. Immedi
ately file claims for loss or damage, either shipping or concealed, with the shipping company.
Check the unit nameplate to verify the model number and electrical characteristics are correct. In the event an incorrect unit
is shipped, it must be returned to the supplier and must NOT
be installed. The manufacturer disclaims all responsibility for
the installation of incorrectly shipped units.
Codes and Regulations
This product is designed and manufactured to permit installation in accordance with National Codes. System design
should, where applicable, follow information presented in
accepted industry guides such as the ASHRAE Handbooks. It
is the installer' s responsibility to install the product in accor
dance with National Codes and/or prevailing local codes and
regulations. The manufacturer disclaims all responsibility for
equipment installed in violation of any code or regulations.
Important Message to the Installer
This equipment is to be installed by an experienced installation
company and fully trained personnel. Carefully read all
instructions and take into account any special considerations
prior to installing the unit. Give this manual to the owner and
explain its provisions.
-
-
-
Important Message to the Owner
Read these instructions carefully and keep them near the product for future reference. Although these instructions are
addressed primarily to the installer, useful maintenance infor
mation is included. Have the installer acquaint you with the
operation of the product and periodic maintenance require
ments.
Recognize Safety Symbols, Words, and Labels
The following symbols and labels are used throughout this
manual to indicate immediate or potential hazards. It is the
owner's and installer's responsibility to read and comply with
all safety information and instructions accompanying these
symbols. Failure to heed safety information increases the risk
of property damage and/or product damage, serious personal
injury or death. Improper installation, operation and mainte
nance can void the warranty.
DANGER
Immediate hazards which WILL result in property
damage, product damage, severe personal injury and/
or death.
WARNING
Hazards or unsafe practice CAN result in property
damage, product damage, sever personal injury and/or
death.
CAUTION
Hazards or unsafe practices which CAN result in
property damage, product damage, and/or personal
injury.
Replacement Parts
Replacement parts can be obtained by contacting McQuay at
1-800-
37-PARTS. When contacting McQuay for service or
replacement parts, refer to the model number and serial num
ber of the unit as stamped on the nameplate attached to the
unit.
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-
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Page 4 IM-806
GENERAL WARNINGS
DANGER
CARBON MONOXIDE (CO) POISONING HAZARD
CO can cause brain damage and death. It is odorless
and colorless. Do not install this unit in any enclosure
or location where fumes many enter an enclosure.
DANGER
To avoid property damage, personal injury or death, do
not store or use gasoline or other flammable vapors or
liquids in the vicinity of this unit or in any area sharing
ventilation.
WARNING
IF YOU SMELL GAS
• Immediatly evacuate the area.
• Do not try to light any appliances.
• Do not touch any electrical switches.
• Do not use any phones in your building.
• Immediately call your gas supplier from a phone
located in a neighboring building.
• Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire
department.
Failure to follow these instructions can result in fire,
explosion, severe personal injury or death.
WARNING
If overheating occurs or the gas supply fails to shut off,
turn off the manual gas shutoff valve outside the
furnace before turning off the electricity supply to avoid
property damage, severe personal injury or death.
WARNING
To avoid property damage, personal injury or death, do
not use this unit if any part has been under water.
Immediately call a qualified service technician to
inspect the furnace and replace any affected part.
WARNING
This product contains or produces substances which
may cause serious illness or death, and which are
known to the State of California to cause cancer, birth
defects or other reproductive harm.
WARNING
To avoid property damage, personal injury or death,
follow the planned maintenance instructions provided in
the "Maintenance" section of this document.
CAUTION
Freezing can burst pipes. Routinely inspect and
monitor unit and premise. If vacant, drain all water
pipes and close water source. Drain hydronic coils and
use alternative heat source.
CAUTION
Do not use this unit as a "construction heater" during
finishing phases of construction on a new structure.
Extremely low return air temperatures and corrosive or
dirty atmosphere can damage unit.
CAUTION
Sheet metal parts, screws, clips and similar items have
sharp edges. Use caution and wear protective clothing
when installing or servicing this equipment.
CAUTION
Keep these instructions in a safe and accessible space
for future reference or in case of an emergency.
IM-806 Page 5
DIMENSIONAL DATA
Figure 1. Vertical and Horizontal Discharge
All dimensions in inches; no scale
Vertical Discharge
(Factory Configuration)
40
17 9/32
74 9/16
A
74 9/16
17 9/32
5 7/8
18
4
18
28 11/16
Horizontal Discharge
(With Field Installed
Accessory)
17 9/32
MODEL A
HEIGHT
Table 2: Horizontal discharge (with field
installed accessory)
Model
090
102
Height
120, 150
090 36 12 1/2 17 9/16
180
*Field Installed Accessory.
120 52 20 1/4 25 13/16
36 12 1/2 17 9/16
A
Supply Air
52 20 1/4 25 13/16
SUPPLY
B
B
AIR
C
Return Air
*
RETURN
AIR
C
40
3/4
*
17 9/32
7/8
C
1 9/32
B
3 25/32
Page 6 IM-806
COMPONENT LOCATION
Figure 2. Typical Component Location
CLEARANCES
Keep adequate clearance around the unit for service, maintenance and proper unit operation. Keep a total clearance of 75"
on the main control panel side of the unit to facilitate possible
fan shaft, coil, electric heat and gas furnace removal (Figure
3). Keep a clearance of 48"on all other sides of the unit to
facilitate possible compressor removal, to allow service access
and to provide proper ventilation and condenser airflow. The
unit must not be installed beneath any obstruction. The unit
must be installed away from all building exhausts, windows,
vents and other entrances to any enclosure. Exhaust air must
not enter an enclosure or any unit fresh air intake
DANGER
CARBON MONOXIDE (CO) POISONING HAZARD
CO can cause brain damage and death. It is odorless
and colorless. Do not install this unit in any enclosure
or location where fumes many enter an enclosure.
Figure 3. Minimum Clearance — Gas Heat Units
.
GAS HEAT UNITS
1. As indicated in Figure 3 and on the unit's nameplate, a minimum clearance of 36" to any combustible material is
required on the furnance access side of the unit. All com
-
bustible materials must be kept out of this area.
2. This 36" clearance must also be maintained to provide
proper combustion air and flue gas flow. The combustion
air intake and furance flue discharge must not be blocked
for any reason, including blockage by snow.
3. Adequate clearances from the furnace flue discharge to any
adjacent public walkways, adjacent buildings, building
openings or openable windows must be maintained in
accordance with the latest edition of the National Fuel Gas
Code (ANSI Z223.1)
4. A minimum horizontal clearance of 48" from the furnace
flue discharge to any electric meters, gas meters, regulators
and relief equipment is required.
Note: Model RG090 through 120 rooftop units are
designed for outdoor installation only. They may be
installed over wood flooring or over Class A, B or C
roof covering materials.
48"
36"
Min.
75"
IM-806 Page 7
48"
48"
ROOF CURB ASSEMBLY
& INSTALLATION
GENERAL
1. Roof curbs are shipped unassembled. Field assembly,
squaring, leveling and mounting on the roof structure are the
responsibility of the installing contractor. All curb installatons
must comply with local codes and should be done in accor
dance with the established guidelines of the National Roofing
Contractors Association.
2. All required hardware necessary for the assembly of the
sheet metal curb is included in the curb accessory.
3. Full perimeter type curb accessories are available. Cantile-
ver type curbs are not available from the factory. Dimensions shown can be used for fabrication in the field. The
full perimeter curb (PGC-5) includes a duct connection
frame to be assembled with the curb. A separate duct con
nection frame can be constructed for use with the cantilever
curb. The unit can be set on the cantilever curb so that
either the condenser end or the two sides overhang the
curb.
-
-
4. Assemble the duct connection frame accessory as shown in
Figure 6. Fasten the pieces together using the sheet metal
screws provided (3/8" hex head).
Note: The duct connection frame can be oriented two ways
when set into the curb. The frame position must cor
respond to the intended unit orientation on the curb.
The gasket provided with the duct connection acces
sory should be applied after duct installation. Refer
to the "Vertical Discharge Duct Connections" sec
tion of these instructions.
Figure 4. Cantilever Curb Joint
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-
-
4. Curbs must be supported on at least two parallel sides by
roof members. Roof members must not penetrate supply
and return duct opening areas.
5. Curb insulation, cant strip, flashings and general roofing
materials are to be furnished by the contractor. Wood nail
ing strip and curb gasketing are furnished with the curb
accessory.
6. The unit and curb accessories are designed to allow vertical
duct installation before unit placement. Do not install duct
after unit placement.
ASSEMBLY
CAUTION
All curbs look similar. To avoid incorrect curb
positioning, check job plans carefully and verify
markings on the curb assembly. Instructions may vary
with curb styles and supersede the information shown.
Cantilever Curb:
1. Position the perimeter pieces, items 1 and 2, as shown in
Figure 4. Check the lengths of all pieces against the bill of
material to verify proper placement and assembly.
2. Assemble side channels, item 1, to the front and back channels, item 2, using bolts, washers, lock washers, and nuts
(items 3, 4, 5 and 6). Hand tighten ONLY at this time.
Figure 5. Typical Curb Installation
-
Table 3: Curb Dimensions
Curb Type A B C
Cantalever 45" 63 1/2" 77 13/16"
Full Perimeter 63 6/16" 63 9/16" 89 7/8"
Figure 6. Cantilever Curb Duct Connection Accessory
3 5/8"
18 23/32"
3 9/32"
18 23/32"
40 23/32"
Note: Flanges on item 1 must go outside of item 2 and
under the wood nailer strip. Curb styles may vary, so
check the curb instructions.
3. Referring to Table 3 and Figure 5, the assembled roof
mounting curb should now be checked for squareness. The
curb assembly must be adjusted until both diagonal mea
surements, dimension "C", are equal within a tolerance of
1/8". All hand tightened fasteners should now be fully
secured.
Page 8 IM-806
Full Perimeter Curb:
R
1. Position perimeter pieces, item A, as shown in Figures 7
and 8. All perimeter pieces are identical.
2. The duct connection frame, items B and C, should be
assembled with the curb as shown in Figures 7 and 8.
Note: The top of the duct connection frame must be flush
with the top of the curb as shown in Figure 7.
3. Fasten the pieces together using the sheet metal screws
provided (item D). Use three screws at each corner of the
curb frame (item A), when positioned, and two screws at
each joint of the duct connection members (items B and C).
4. The assembled roof mounting curb should now be checked
for squareness. Referring to Table 3 and Figure 5, the curb
assembly must be adjusted until both diagonal measure
ments (dimension "C") are equal within a tolerance of 1/8".
5. Gasket material sufficient to seal the curb perimeter and the
duct connection frame is included and attached to a duct
connection member
.
Figure 8. Full Perimeter Curb Detail
18-23/32
3-9/32
18-23/32
Note: Do not apply gasket material to the curb perimeter
and the duct connection frame until the ducts are
placed in the frame. Refer to the "Vertical Discharge
Duct Connections" section of these instructions.
Figure 7. Full Perimeter Curb
-
40-23/32
63-9/16
68-1/16
4
1
2
68-1/16
63-9/16
2-1/4
3-1/4
1-1/2
5-1/2
3-1/4
UNIT BOTTOM
2-1/4
14
4
1
3-1/2
2
26-5/32
3
9-5/8
WOOD NAILER
SUPPLIED
WITH CURB
3
4
DUCT
SUPPORT
(B)
1-1/2
CURB
PERIMETER
(A)
GASKETING BETWEEN
SUPPLY AIR
3-9/32
NOT SHOWN: INSULATION, CANT STRIP,
FLASHING AND ROOFING MATERIALS
BY OTHERS
UNIT & CURB
DUCT
SUPPORT
(C)
RETURN AI
FIELD SUPPLIED
DUCT
IM-806 Page 9
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