Installation and Maintenance Manual IM-810
SAH Air Handler
1-1/2 to 5 Tons
Group: Unitary
Part Number: IM-810
Date: August 2005
Supersedes: March 2005
© 2005 McQuay International
IM-810 Page 1
Table of Contents
M
S
N
1
2
3
3
3
4
4
4
6
61 = 5
g
MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Codes and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Message to the Installer . . . . . . . . . . . . . . . . . . . . 3
Important Message to the Owner . . . . . . . . . . . . . . . . . . . . 3
Recognize Safety Symbols, Words, and Labels . . . . . . . . . . 3
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HKR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
For All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL SUPPLY WIRE AND MOP . . . . . . . . . . . . . . 6
Inspection of the Building Electrical Service . . . . . . . . . . . . . 6
Wire Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maximum Overcurrent Protection (MOP) . . . . . . . . . . . . . . . 7
Electrical Connections – Supply Voltage . . . . . . . . . . . . . . . 7
Air Handler Only (Non-Heat Kit Models) . . . . . . . . . . . . . . . .7
Air Handler With Non-Circuit Breaker Heat Kits . . . . . . . . . .7
Air Handler With Heat Kits Containing a Circuit Breaker. . . .7
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .7
REFRIGERANT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tubing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Post Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Piping Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Evaporator Coil Metering Devices . . . . . . . . . . . . . . . . . . . . .7
Conversion to Downflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conversion To Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Condensate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
ACHIEVING A 2% LOW LEAKAGE RATE . . . . . . . . . . . . .10
Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Two-Stage Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
THERMOSTAT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
"McQuay" is a registered trademark of McQuay International.
"Illustrations and information cover the McQuay International products at the time of publication and we reserve the right to make changes in
design and construction at any time without notice."
© 2005 McQuay International
MODEL NOMENCLATURE
SAH 018
odel
AH= Split Air Handler Unit
ominal Capacity (tons)
8 = 1-1/2
4 = 2
0 = 2-1/2
2 = 2-1/2
6 = 3
2 = 3-1/2
8 = 4
9 = 4
0 = 5
Page 2 IM-810
A
RFY
Future Use
Refrigerant Meterin
F = Flowrater
T = TXV
Voltage/Phase
R = 208-230/1/60
Vintage
Table 1: Unit Nameplate Model Number Identifier
Unit Nameplate McQuay Model Number
ARUF018-00A-1/-1A SAH018ARFY
ARUF024-00A-1/-1A SAH024ARFY
ARUF030-00A-1/-1A SAH030ARFY
ARUF032-00A-1/-1A SAH032ARFY
ARUF036-00A-1/-1A SAH036ARFY
ARUF042-00A-1/-1A SAH042ARFY
ARUF048-00A-1/-1A SAH048ARFY
ARUF049-00A-1/-1A SAH049ARFY
ARUF060-00A-1/-1A SAH060ARFY
ARUF061-00A-1/-1A SAH061ARFY
ARPT024-00C-1/00C-1A SAH024ARTY
ARPT032-00C-1/00C-1A SAH032ARTY
ARPT036-00C-1/00C-1A SAH036ARTY
ARPT042-00C-1/00C-1A SAH042ARTY
ARPT049-00C-1/00C-1A SAH049ARTY
ARPT061-00C-1/00C-1A SAH061ARTY
INTRODUCTION
General Description
These installation instructions cover the indoor installation of
1-1/2 to 5 ton multi-position air handlers. See the product catalog for information regarding specifications applicable to
your model and accessories.
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. Immediately 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 accordance 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
The United States Environmental Protection Agency
(EPA) regulations cover introduction and disposal of
refrigerants in this unit. Failure to follow those
regulations can harm the environment and lead to
substantial fines. Because regulations can change, a
certified technician should perform any work done on
this unit. If you have any questions, please contact the
local office of the EPA.
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 information is included. Have the installer acquaint you with the
operation of the product and periodic maintenance requirements.
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 maintenance can void the warranty.
IM-810 Page 3
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 number of the unit as stamped on the nameplate attached to the
unit.
GENERAL WARNINGS
WARNING
This product is factory shipped for use with a 208-230/
1/60 electrical power supply. This air handler must not
be reconfigured to operate with any other power supply.
Failure to observe this warning may result in personal
injury, equipment damage and fire.
WARNING
When installing or servicing this equipment wear
protective gloves, gear and eyeware. Also observe
special safety requirements (hard hats etc.).
PRODUCT DESCRIPTION
These air handlers are designed to be installed in upflow,
downflow, and horizontal right orientations.
These air handlers are designed for indoor use only and must
only be installed in a weatherized area. DO NOT INSTALL
OUTDOORS. Typical installations for this product include:
• Overhead (attic/mezzanine, etc.)
• Closet/mechanical room/basement/crawl space.
Other applications are acceptable, provided they comply with
this manual and local/state codes.
DANGER
CARBON MONOXIDE (CO) POISONING HAZARD
CO can cause brain damage and death. It is odorless
and colorless. The installation area must be properly
vented and joints must be tight so CO cannot enter
ductwork or enclosed space.
WARNING
Before servicing or installing this equipment, the
electrical power to this unit must be in the "OFF"
position. More than one disconnect may exist. Failure
to disconnect power can cause electrical shock, serious
personal injury or death.
WARNING
The unit must have an uninterrupted, unbroken
electrical ground. Failure to properly ground can cause
severe personal injury or death.
WARNING
Installation and service by trained, qualified technicians
only. High pressure and electricity can cause severe
personal injury or death. Observe ALL warnings
contained in this manual and the labels/tags attached to
the equipment.
When matched with a McQuay brand condenser or heat pump,
an ARI certified rating is available for many combinations.
Electric heat is available for all models. This is an accessory
and is not provided with the equipment. Use only the electric
heat kits identified in the “Electric Heat” section of this manual.
These air handlers are intended for use with a room thermostat.
The thermostat is not supplied with this equipment. Thermostats that use 24 VAC operating voltage must be used.
ELECTRIC HEAT
WARNING
To avoid personal injury, fire and property damage, refer
to the “Installing Electric Heat” section of this manual for
the correct installation procedure.
WARNING
The electrical characteristics of the air handler, the
electric heat kit, and the supply power must agree.
Failure to observe this warning can result in equipment
damage, fire and property damage.
This air handler does not have factory-installed electric heat.
Electric heat is available as an accessory. If installing this
option, only the HKR series heat kits can be used. See the
product catalog to determine the HKR Kit applicable to your
air handler and application.
The heating mode temperature rise is dependent upon the system airflow, the supply voltage and the heat kit size (kW)
selected. Use Tables 2-4 to determine the temperature rise (
Page 4 IM-810
o
F).
Table 2: 230/1/60 Supply Voltage Temperature Rise (°F)
CFM
60018283541
8001321263142
1000 11 17 21 25 34 50
1200 9 14 18 21 28 42 56 62
1400 8 12 15 18 24 36 48 53
1600 7 10 13 15 21 31 42 46
1800 6 9 12 14 19 28 37 41
2000 5 8 11 12 17 25 34 37
356810152021
Heat Kit Nominal kW
HKR INSTALLATION
DANGER
CARBON MONOXIDE (CO) POISONING HAZARD
CO can cause brain damage and death. It is odorless
and colorless. The installation area must be properly
vented and joints must be tight so CO cannot enter
ductwork or enclosed space.
Do not operate this product without all ductwork
attached.
Table 3: 220/1/60 Supply Voltage Temperature Rise (°F)
CFM
60017273439
8001320253040
1000 10 16 20 24 32 48
1200 8 13 17 20 27 40 53 59
1400 7 11 14 17 23 34 46 51
1600 6 10 13 15 20 30 40 44
1800 6 9 11 13 18 27 36 39
2000 5 8 10 12 16 24 32 35
356810152021
Heat Kit Nominal kW
Table 4: 208/1/60 Supply Voltage Temperature Rise (°F)
CFM
60016253237
8001219243838
1000 10 15 19 22 30 46
1200 8 13 16 19 25 38 51 56
1400 7 11 14 16 22 33 43 48
1600 6 9 12 14 19 28 38 42
1800 6 8 11 12 17 25 34 37
2000 5 8 10 11 15 23 30 34
356810152021
Heat Kit Nominal kW
Note: For installations not indicated above, the following
formula is to be used:
TR = (kW x 3412) x (Voltage Correction) x 1.08 / CFM
Where:TR = Temperature Rise
KW = Heat Kit Actual kW
3412 = Btu per kW
Voltage Correction =.96 (230 Supply Volts)
=.92 (220 Supply Volts)
=.87 (208 Supply Volts)
1.08 = Constant
CFM = Measured Airflow
Note: The Temperature Rise Tables can also be used to
determine the air handler airflow delivery. When
using these tables for this purpose set the room thermostat to maximum heat and allow the system to
reach steady state conditions. Insert two thermometers, one in the return air and one in the supply air.
The temperature rise is the supply air temperature
minus the room air temperature.
WARNING
Verify that all power is disconnected prior to attempting
installation of this heater kit. There may be more than
one disconnect servicing this equipment.
• When installed in a garage, the elements must be at
least 18" above the floor.
• Strain relief and conductor protection must be provided at the supply wire entrance.
• This appliance must be installed following the ANSI/
NFPA70 (National Electrical Code) and other applicable codes. If in doubt, contact the local authority
having jurisdiction.
• Use copper conductors only
• Some localities require the installer be licensed.
Contact the local authority if in doubt.
Failure to follow these instructions can cause fire,
electrical shock, property damage, personal injury or
death.
Follow these instructions when installing the HKR kit. Perform steps 1 through 7 in an open area, before moving the air
handler to its final installation position.
For All Models
1. Turn off the electrical supply to the unit.
2. Remove the upper access panel.
3. Remove the screws that attach the electric heat block-off
panel. Retain these screws. Discard the block-off panels.
4. If the heat kit is equipped with circuit breakers (“C” models), remove the circuit breaker mounting bracket, leaving
the circuit breakers attached.
5. Slide the heater kit into the slot left vacant from step 3 and
secure using the screws removed in step 3. Verify that the
heater is installed with the airflow directional label pointing
in the direction of the discharge air. Steps 6 through 8 and
Step 11 relate to circuit breaker models only. For kits that
do not contain circuit breakers, perform Steps 9-10 and 12
through 14.
6. Install the circuit breaker mounting panel on the upper
right area of the blower deck. Insert screws through the
blower deck into the mounting panel from the blower side.
The plastic mounting pin on the side of the mounting panel
is inserted into a receiving hole on the side of the air handler cabinet.
IM-810 Page 5
7. The circuit breaker is to be installed in the correct orientation (i.e. the OFF position is down). In downflow applications, remove the circuit breaker from the mounting bracket
and install it 180
o
from the factory direction. Upflow and
horizontal installations require no position changing.
Installation Tip: In some cases it may be easier to wire the
breakers before reinserting them into the mounting panel.
8. Following the HKR wiring diagram, insert the electrical
supply wiring into the lugs provided on the circuit breaker
and tighten. THE ELECTRICAL SUPPLY WIRES MUST
BE ROUTED THROUGH A MEANS OF STRAIN
RELIEF AS THEY ENTER THE CABINET.
9. Remove the multi-pin connector with the jumper wire and
discard. Insert the new wiring harness provided with the
kit. Note: the plug is keyed and can only be installed in
one direction.
10.Insert the supply wire ground conductor into the lug provided with the kit. Verify that this connection is tight.
11.Break out the appropriate area(s) of the plastic circuit
breaker cover on the air handler front panel. Rotate this
panel for downflow applications.
12.The air handler supply wiring and low voltage wiring is to
be connected as shown on the HKR wiring diagram.
13.Install upper access panel removed in step 2.
14.Apply the wiring diagram over the original air handler wiring diagram.
LOCATION
WARNING
This air handler is not weather tight and is designed for
indoor installation only. Do not install outdoors.
When installing this air handler, give careful consideration to
minimizing the length of refrigerant tubing. Do not install the
air handler in a location either above or below the condenser
that violates the instructions provided with the condenser.
Allow a minimum of 24" in front of the unit for service clearance. When installing in an area directly over a finished ceiling
(such as an attic), an emergency drain pan is required directly
under the unit. See local and state codes for additional requirements. When installing this unit in an area that may become
wet, elevate the unit with a sturdy, non-porous material. In
installations that may lead to physical damage, install a protective barrier to prevent equipment damage.
DUCTWORK
This air handler is designed for a complete supply and return
ductwork system.
For proper system performance, size the ductwork to accommodate 375-425 CFM per ton of cooling with a static pressure
not to exceed 0.5" WC. Inadequate ductwork that restricts airflow can result in improper performance and compressor or
heater failure. Construct ductwork in a manner that limits
restrictions and maintains suitable air velocity. Seal ductwork
to the unit in a manner that will prevent leakage.
Return Ductwork. DO NOT TERMINATE THE RETURN
DUCTWORK IN AN AREA THAT CAN INTRODUCE
TOXIC OR OBJECTIONABLE FUMES/ODORS INTO THE
DUCTWORK. The return ductwork is to be introduced into
the air handler bottom (upflow configuration).
DANGER
CARBON MONOXIDE (CO) POISONING HAZARD
CO can cause brain damage and death. It is odorless
and colorless. The installation area must be properly
vented and joints must be tight so CO cannot enter
ductwork or enclosed space.
Do not operate this product without all ductwork
attached.
Return Air Filters. Each installation must include a return
air filter. This filtering may be performed at the air handler or
externally using a return air filter grille. Air handlers mounted
in the downflow orientation require external filtering. A washable filter is available as an accessory. For optimum performance, frequent filter cleaning is advised. Refer to Table 5 for
the appropriate filter.
Table 5: Filter Selections
SAH Model Filter Number Qty. Required
018-032 FIL18-32 1
036-042 FIL36-42 1
048-061 FIL48-61 1
ELECTRICAL SUPPLY WIRE AND
MOP
WARNING
To avoid the risk of fire or equipment damage, use only
copper conductors. Before servicing or installing this
equipment, the electrical power to this unit must be in
the “off” position and all power supplies disconnected.
More than one disconnect can exist. Failure to observe
this warning can result in an electrical shock that can
cause personal injury.
WARNING
The unit must have an uninterrupted, unbroken electrical
ground. Failure to properly ground can cause severe personal injury or death.
The unit must have an uninterrupted, unbroken electrical ground.
The electrical ground circuit may consist of an appropriately
sized electrical wire connecting the ground lug in the unit control box wire to the building electrical service panel. Other
methods of grounding are permitted if performed in accordance with the National Electric Code (NEC)/American
National Standards Institute (ANSI)/National Fire Protection
Association (NFPA) 70 and local/state codes. In Canada, electrical grounding is to be in accordance with the Canadian Electric Code CSA C22.1. Failure to observe this warning can
result in electrical shock that can cause serious personal injury
or death.
Inspection of the Building Electrical Service
This unit is designed for single-phase electrical supply. DO
NOT OPERATE ON A THREE-PHASE POWER SUPPLY.
Measure the power supply to the unit. The supply voltage
must be in agreement with the unit nameplate power requirements and within the range shown in Table 6.
Page 6 IM-810
Table 6: Minimum and Maximum Supply Voltage
Nominal Input Minimum Voltage Maximum Voltage
208/230 187 253
Wire Sizing
Wire size is important to the operation of your equipment. Use
the following checklist when selecting the appropriate wire
size for your unit.
• Wire size must carry the Minimum Circuit Ampacity
(MCA). The unit MCA for the air handler and the optional
electric heat kit can be found on the unit nameplate.
• Wire size allows for no more than a 2% voltage drop from
the building breaker/fuse panel to the unit. Refer to the latest edition of the National Electric Code, or the Canadian
Electric Code (Canada) when determining the correct wire
size. Table 7 shows the current carrying capabilities for
copper conductors rated at 75
o
C with a 2% voltage drop.
Use Table 7 to determine the voltage drop per foot of various conductors.
Table 7: Maximum Allowable Length in Feet to Limit Voltage
Drop to 2%*
Wire Size
(AWG)
14 75 50 37 NR NR NR NR NR
12 118795947NRNRNRNR
10 188 125 95 75 63 54 NR NR
8 301 201 150 120 100 86 75 68
6 471 314 235 188 157 134 118 110
*Based on NEC 1996
10 15 20 25 30 35 40 45
Min. Circuit Ampacity (MCA)
Maximum Overcurrent Protection (MOP)
Every installation must include an NEC (USA) or CEC (Canada) approved overcurrent protection device. Also, check with
local or state codes for special requirements.
This protection can be in the form of fusing or HACR style circuit breakers. The nameplate can be used as a guide for selecting the MAXIMUM overcurrent device.
Note: Fuses or circuit breakers are to be sized larger than
the equipment MCA, but not to exceed the MOP.
Electrical Connections – Supply Voltage
USE COPPER CONDUCTORS ONLY.
A knockout is provided on the air handler top panel or side to
allow for the entry of the supply voltage conductors. An NEC
or CEC approved strain relief is to be used at this entry point.
The wire is to be sized in accordance with the “Electrical Wire
and MOP” section of this manual. Some areas require the supply wire to be enclosed in conduit. Consult your local codes.
Air Handler Only (Non-Heat Kit Models)
The building supply connects to the stripped black and white
wires contained in the air handler electrical compartment cavity. A ground screw is also contained in this area. Attach the
supply wires to the air handler conductors as shown in the unit
wiring diagram using appropriately sized solderless connectors
or other NEC or CEC approved means.
Air Handler With Non-Circuit Breaker Heat Kits
A terminal block is provided with the HKR kit to attach the
supply and air handler connections. Follow the installation
instructions and wiring diagram provided with the HKR heat
kit for complete wiring details.
Air Handler With Heat Kits Containing a Circuit
Breaker.
HKR models with a “C” suffix contain a circuit breaker(s).
The air handler has a plastic cover on the access panel that will
require either one or both sections to be removed to allow the
heat kit circuit breaker(s) to be installed. See the HKR Installation Instructions for further details. The air handler wires and
supply wires are installed directly onto the HKR circuit
breaker(s) as shown in the HKR Installation Manual and wiring diagram.
Low Voltage Connections
Several combinations of low voltage arrangements are available, depending on the presence of a heat kit and whether the
heat kit is single or multi-stage. The low voltage connections
are determined by whether the outdoor unit is a condenser or
heat pump. The 24V-control voltage connects the air handler
to the room thermostat and condenser. Use copper conductors
for low voltage wiring. A minimum of 18AWG must be used
for installations up to 50 feet and 16AWG for installations over
50 feet. Low voltage wiring can be made through the top of
the cabinet or through either side. See the “Thermostat Wiring” section of this manual for typical low voltage wiring connections.
REFRIGERANT LINES
CAUTION
When welding close to the painted surfaces, use a
quenching cloth to prevent scorching or marring of
equipment finish.
Tubing Preparation
All cut ends are to be round, burr free, and cleaned. Failure to
follow this practice increases the chances for refrigerant leaks.
The equipment suction line(s) are spun closed and require pipe
cutters to cut off the closed end.
Use solder with a minimum of 5% silver.
Post Brazing
Quench all welded joints with water or a wet rag.
Piping Size
For the correct size tubing, follow the specification for the condenser/heat pump.
WARNING
This coil is shipped under pressure. Follow instructions
included in this manual (pages 8 and 9) to avoid personal
injury.
Evaporator Coil Metering Devices
Flowrater Model
For most installations, no change to the flowrater orifice is
required. In mix-matched applications (the condenser/heat
pump is a different tonnage than the air handler), a different
flowrater orifice may be required (Figures 1 and 2). See the
piston kit chart in the Condensing Unit Catalog. Consult your
local representative for the details regarding mix-matched orifice sizing.
IM-810 Page 7
1. Loosen the 13/16" nut 1 TURN ONLY. No pressure loss
indicates a possible leak.
2. Remove the nut and discard the black or brass cap.
3. Remove the check piston to verify it is correct. See the piston kit chart in the Condening Unit Catalog.
4. Use a tube cutter to remove the spin closure on the suction
line.
5. Remove the tailpiece clamped to the exterior.
6. Slide the 13/16" nut into position. Braze the tailpiece to the
liquid tube.
7. Insert the suction line into the connection. Slide the insula-
tion and the rubber grommet at least 18" away from the
braze joint.
8. AFTER THE TAILPIECE HAS COOLED, position the
white Teflon seal and hand tighten the nut.
9. Torque the 13/16" nut to 20-30 ft-lbs. [2.77-4.15 meter kg].
10.Replace the suction line grommet and insulation.
Figure 1. Replacing Flowrater Orifice
8. AFTER THE TAILPIECE HAS COOLED, position the
white Teflon seal and hand tighten the nut.
9. Torque the 13/16" nut to 20-30 ft-lbs. [2.77-4.15 meter kg].
10.Replace the sensing bulb to the horizontal portion of the
suction line (Figure 3), just inside cabinet. Place the bulb
parallel with suction line in the 10 o’clock position. If the
10 o’clock position is inaccessible, place in the 2 o’clock
position. Secure the bulb to the line with strapping provided in the literature envelope. Insulate the sensing bulb
to the line with self-adhesive insulation provided in the
envelope.
11.Replace the access panel, suction line grommet, and insulation.
Figure 3. Sensing Bulb Location
Figure 2. Suction Line
TXV Model
IMPORTANT: The sensing bulb is not permanently installed
in the factory. To prevent damage, remove this bulb prior to
brazing. Place it in the proper location after the braze joint has
cooled (Figure 3).
1. Loosen the 13/16" nut 1 TURN ONLY. No pressure loss
indicates possible leak.
2. Remove the nut and discard the black or brass cap.
3. Remove the large front panel and remove the sensing bulb
from suction manifold. TO PREVENT DAMAGE TO THE
SENSING BULB, VERIFY THAT THE BULB IS NOT
NEAR THE FLAME OR IN CONTACT WITH THE SUCTION LINE OR MANIFOLD DURING BRAZING.
4. Use a tube cutter to remove the spin closure on the suction
line.
5. Remove the tailpiece clamped to the exterior.
6. Slide the 13/16" nut into position (Figure 1). Braze the tail-
piece to the liquid tube.
7. Insert the suction line into the connection. Slide the insula-
tion and the rubber grommet at least 18" away from the
braze joint.
For the majority of installations, no adjustment to the TXV setting is required. However, if the measured superheat is less
than 8°F or greater than 20°F, an adjustment is required. The
adjustment stem is at the base of the valve (opposite the diaphragm) under the flare nut.
To increase the superheat (measured at the condenser base
valve), turn the stem clockwise (in). To decrease the superheat,
turn the stem counterclockwise (out). Use a ¼" refrigeration
wrench for this function.
Note: Design point for the system is 10°F of superheat
(measured at the condenser base valve) at 95°F outdoor air.
Charging Note:
Air handlers with a TXV should be charged to
15°F of subcooling at the indoor inlet. This supercedes any subcooling value listed in the condensing unit literature.
Conversion to Downflow
Perform the conversion to downflow before placing the air
handler in its final location. The location must allow for access
to all sides. To prevent the evaporator coil pan from “sweating,” use the DPI accessory insulation kit when performing
this conversion. Note: The DPI kit is not supplied
product and must be purchased separately. See Table
the correct DPI kit.
Table 8:
SAH Model Insulation Kit
018-032 DPI18-302
036-042 DPI36-422
048-061 DPI48-612
with this
8 for
Page 8 IM-810
Refer to Figures 4 through 6 for the location of the compo-
)
nents referenced in the following steps. Figure 4 illustrates the
new installation location for the removed components.
1. Before inverting the air handler, remove all access panels,
the coil rear channel bracket, and the filter close-off panel.
2. Remove the evaporator coil and the horizontal drain pan.
Discard the horizontal drain pan.
3. Install the provided plastic plug into the vacated access
panel.
4. Remove the two (2) zee coil support brackets and insulation retaining brackets.
5. Remove the tie bracket.
6. Install the DPI Insulation Kit onto the bottom of the drain
pan.
Figure 4. Removed Componants Locations
NOTE: The filter provision is not applicable in
this downflow application.
7. Install the zee coil supports and the wrapper stiffeners.
8. Install the tie bracket.
9. Install the rear channel bracket.
10.To prevent possible condensate “blow off”, lay the insulation retainers into the evaporator coil pan as shown in Figure 5.
Figure 5. Insulation Retainers
Figure 6. Conversions to Downflow
TOP OF WRAPPER
INSULATION JACKET
ZEE COIL SUPPORT
WRAPPER STIFFENER
DRAIN PAN INSULATION
DPI KIT (HATCHED AREA
BLOWER
NEOPRENE GASKET
MOTOR
Conversion To Horizontal
The following describes converting to “Horizontal LeftHand”. The only field modification required for conversion to
“Horizontal Right-Hand” is the removal of the plastic knockouts in the horizontal panel drain connections.
The conversion to horizontal left-hand (Figure 7) should be
performed before placing the air handler in its final location,
and in an area that allows for access to all sides.
1. Remove the (3) air handler access panels.
2. Remove the “J” shaped bracket that retains the evaporator
coil.
3. Remove the flowrater (or TXV) from the lower left side
access panel and slide out the evaporator coil and horizontal drain pan.
4. Remove the gasket from the horizontal pan drain connections.
5. Remove the oval shaped plastic plug from the left side
access panel. Remove the oval shaped rubber gasket seal
from the lower right side access panel.
6. The drain connections for the horizontal pan are sealed
with a thin coating of plastic. Carefully knock out this
plastic seal with a screwdriver and hammer.
Note: The upper drain will become the secondary drain
which is mandatory in many municipalities .
7. Install the plastic plug removed in step 5 in the right side
lower access panel and the oval shaped rubber gasket in the
To complete the conversion, slide the evaporator coil into the
chassis and attach the three (3) access panels. (Figure 6).
lower left access panel.
8. Reinstall the evaporator coil with the horizontal panel on
the left side. Note: Push the assembly completely to the
rear to verify the engagement of the upflow pan with the
rear channel bracket.
IM-810 Page 9
9. Install the “J” bracket (removed in step 2) to support the
upflow pan to the tie channel.
that the flowrator gasket is installed on the lower access panel.
An additional drain hole cover is required.
10.Attach all panels and the refrigerant management device.
Figure 7. Conversion to Horizontal Left-Hand
Condensate Removal
The drain pan has a primary and secondary drain connection
(Figure 7). Condensate removal is performed by attaching a
¾” PVC pipe to the evaporator coil pan and terminated in
accordance with local or state codes. The installation must
include a “P” style trap that is located as close as possible to
the evaporator coil. To prevent possible damage to the evaporator drain pan do not over-tighten the drain connection(s).
See Figure 8 for an illustration of a typical condensate line “P”
trap.
Installations that are above a finished ceiling may require a
field-supplied auxiliary drain pan. Consult local codes on this
requirement.
Figure 8.
HUMIDITY CONTROL
When using a Humidistat (normally closed), cut jumper PJ6 on
the control board. The Humidistat will only affect cooling airflow by adjusting the airflow to 85%.
TWO-STAGE HEATING
When using staged electric heat, cut jumper PJ4 on the control
board.
THERMOSTAT WIRING
Use the thermostat wiring diagram (Figures 9 thru 12) and
those provided with the thermostat when making connections.
Figure 9. Low Voltage Wiring Diagram for Cooling Unit With
Optional Heat Kit (10KW and below)
Figure 10. Low Voltage Wiring Diagram for Cooling Unit With
Optional Heat Kit (15KW and above)
Use of a condensate removal pump is permitted when necessary. This condensate pump should have provisions for shutting off the control voltage in the event of the drain becoming
blocked. A trap must be installed between the unit and the condensate pump.
IMPORTANT: The evaporator coil is coated with oils that
may dissolve Styrofoam and certain types of plastics. A
removal pump or float switch must not contain any of these
materials.
Installation Tip: Priming the “P” trap may avoid improper
draining at the initial installation and at the beginning of the
cooling season.
ACHIEVING A 2% LOW LEAKAGE
RATE
Verify that the Neoprene gasket with PSA remains intact on all
surfaces where the access panels are secured. These surfaces
are the entire length of the wrapper and areas between the
upper tie plate, and the upper and lower access panels. Verify
that the upper access panel breaker insert gasket is intact, and
Page 10 IM-810
Thermostats
Note: Second stage heat can be accomplished by using a
multi-stage heating thermostat or using an outdoor
thermostat as shown in Figures 11 and 12.
McQuay part number CHT18-60 is a single-stage cool and single-stage heat thermostat.
McQuay part number HPT18-60 is a single-stage cool, twostage heat pump thermostat. The first stage is heat pump heating and the second stage is optional electric heat.
If additional features are desired, such as digital or programmable capabilities, these thermostats are commercially available. Follow the thermostat manufacturer’s instruction for
installation.
Start-Up Procedure
• Prior to start-up, verify that all electrical connections are
properly sized and tightened.
• All panels must be in place and secured. For air tight application, neoprene gasket must be positioned at prescribed
• The unit is protected from vehicular or other physical damage.
• The return air is not obtained from any areas where there
may be objectionable odors, flammable vapors or products
of combustion such as carbon monoxide (CO), which may
cause serious personal injury or death.
locations to achieve 2% leakage.
• The tubing must be leak free.
Regular Maintenance
• The unit should be elevated, trapped and pitched to allow
for drainage.
• The low voltage wiring is connected.
• The auxiliary drain is installed, when necessary, and
pitched to allow for drainage.
• The drain pan and drain tubing has been leak checked.
• The return and supply ducts are sealed.
• The unit is elevated when installed so water cannot accumulate.
• No flammable vapors can be present.
Figure 11. SAH 1-1/2 to 5 Ton System Composite Diagram - 10 kW and Below
To avoid electrical shock and personal injury, disconnect
all power supplies before performing any service. Note
that there may be more than one power supply.
The only item to be maintained on a regular basis by the user is
the circulating air filter(s). Filters should be cleaned or
replaced regularly. A certified service technician must perform all other services.
WARNING
Heat Pump
W2
C
BL
W
OYR
OR
(optional) Make On Fall
R
Y
R
Y
OR
W
BL
Outdoor Thermostat
Conventional
Room Thermostat
O
#18 GA. 5 Wire
W2
CY
BL
#18GA. 6 Wire Needed When
Outdoor Thermostat Is Used
GE
R
See
Note 3
W
BR
BL
R
GR
#18 GA. 7 Wire
Pink
IM-810 Page 11
Figure 12. SAH 1-1/2 to 5 Ton System Composite Diagram - Above 10 kW
e
Heat Pump
W2
C
BL
OYR
OR
W
R
Y
R
Y
OR
W
BL
#18 GA. 5 Wire
OT1
Note
OT2
#18GA. 7 Wire Needed When 2
Outdoor Thermostat Are Used
NOTES:
1. Outdoor Thermostat (OT1) should be the first
to close and the first to open.
2. Install jumper if Outdoor Thermostat (OT2) is
not used.
3. Remove wire when using Outdoor Thermostat.
#18 Ga. 7 wire needed when (2) OTs are used.
Conventional
Room Thermostat
CY
O
W2 G E
See
Note 3
R
GR
W
1
EHR
4
BL
NOMENCLATURE :
OT - Outdoor Thermostat (Optional)
MOF - Make On Fall
EHR - Emergency Heat Relay (Optional)
#18 GA. 7 Wire
R
See
Note 2
2
3
BR
AR Indoor Unit
Pink
COLOR CODES
R - Red OR - Orang
Y - Yellow W - White
BL - Blue G- Green
BR - Brown
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.
www.mcquay.com • 800-432-1342
Page 12 IM-810
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