McQuay SWP 018, SWP 023, SWP 028, SWP 035, SWP 040 Installation Manual

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Installation and Maintenance IM-708

Self-contained Air Conditioning System

Type SWP Vintage Sizes 18D thru 95D, 105E

MEA

Group: Applied Systems Part Number: IM708 Date: February 2002

368-93-E

Table of Contents

Introduction

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

SWP-055-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Setting Factory Supplied Plenum. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Location/Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Shipping Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . 6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Condenser Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Supply Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Return Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . 11

Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Unit Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Return Air and Outside Air Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 14

Supply Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Lug Sizes For Single Disconnect or Power Block . . . . . . . . . . . . . 16

Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical Legend . . . . . . . . . . . . . . . . . . . . . . . . . 18

Typical Wiring Schematics . . . . . . . . . . . . . . . . . . 19

Figure 19. Power Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Figure 20. Input Schematic, Discharge Air Control (DAC). . . . . . . 20

Figure 21. Input Schematic, Zone or Space Comfort Control (SCC) 21

Figure 22. Output Schematic, Actuator Control . . . . . . . . . . . . . . 22

Figure 23. Output Schematic, Auxiliary Fan Start/Stop Control . . 23

Figure 24. Output Schematic, Actuator Control . . . . . . . . . . . . . . 24

Figure 25. Output Schematic, Compressor Control (4 Compressors/4,

5 or 6 Stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 26. Output Schematic, Compressor Control (6 Compressors /

6 Stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Standard Controls . . . . . . . . . . . . . . . . . . . . . . . . . 27

High Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Low Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Compressor Motor Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Proof of Airflow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Frost Protection Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Clogged Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Duct High Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Phase Fail/Under Voltage Protection . . . . . . . . . . . . . . . . . . . . . . 28

Duct Static Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Building Static Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Building pressurization applications . . . . . . . . . . . . . . . . . . . . 29

Freezestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Condenser Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Water Side Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Condenser Water, Head Pressure Control. . . . . . . . . . . . . . . . . . . 30

Variable Inlet Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Adjustable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dual Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Hot Water Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

System Check, Test and Start . . . . . . . . . . . . . . . 31

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Pre Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fan start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Compressor start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Economizer start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Hot water start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Expansion valve superheat adjustment . . . . . . . . . . . . . . . . . 32

Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Variable air volume (VAV) start-up . . . . . . . . . . . . . . . . . . . . 34

Rpm changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Drive sheave alignment and belt tension . . . . . . . . . . . . . . . . 34

Final control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Maintaining control parameter records . . . . . . . . . . . . . . . . . 35

System Maintenance . . . . . . . . . . . . . . . . . . . . . . . 36

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . 37

Service and Warranty Procedure . . . . . . . . . . . . . 38

In Warranty Return Material Procedure . . . . . . . . . . . . . . . . . . . . . 38

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Check, Test and Start Procedure Form . . . . . . . . 39

2 IM708

Introduction

General Description

Models SWP018 through 105 are factory assembled, refrigerant charged and tested, water cooled packaged air conditioning units designed for ducted applications.

Each unit contains multiple hermetic compressors, water cooled condensers, multi-circuit evaporator, thermal expansion valves, interconnecting refrigerant piping, forward curved centrifugal fan, belt drive, fan motor, pleated filters and all necessary operating and safety controls.

All rigging, installation, power and control wiring external to the unit, and condenser water and condensate piping are the responsibility of the installer.

The MicroTech II self-contained unit controller is standard equipment. For a detailed description of the MicroTech II components, input/output configurations, field wiring options and requirements, and service procedures, refer to Bulletin No. IM 710, "MicroTech II Self-contained Unit Controller." For a description of operation and information on using and programming the MicroTech II unit controller, refer to the appropriate operation manual (see Table 1).

Table 1: Self-contained unit operation manual literature

UNIT CONTROL CONFIGURATION

Variable Air Volume (VAV) Discharge Air Control (DAC)

Constant Air Volume Space Comfort Control (SCC)

Constant Air Volume Discharge Air Control (DAC)

OPERATION MANUAL

BULLETIN NUMBER

OM711

OM712

OM711

Inspection

When the equipment is received, all items should be carefully checked against the bill of lading to insure a complete shipment. The shipping receipt should not be signed until all items have been accounted for. All units should be carefully inspected for damage upon arrival. All shipping damage should be reported to the carrier and a claim filed. The unit serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available.

Nomenclature

SWP-055-D

Self-contained Water cooled Plenum discharge

IM708 3

Vintage

Nominal tons

Installation

Note: Installation and maintenance are to be performed

only by qualified personnel who are familiar with local codes and regulations, and experienced with

this type of equipment.

CAUTION

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

Handling

Units are shipped with a protective covering which should remain in place while the unit is being moved to its final location. Note: Check for concealed damage as soon as possible.

Never allow any part of the unit to fall during unloading or moving as this may result in serious damage. Units are provided with lifting lugs for rigging with a crane. If units are lifted by crane, protection against chaffing damage by slings or cable must be provided and spreader bars must be used across the top of the cabinet to prevent any structural damage to the frame.

The unit base frame will accept dollies or Johnson bars for transporting the unit. Furniture dollies can be placed at both ends of the chassis or at one end and a Johnson bar used at the other end for maneuvering.

CAUTION

required. Foam rubber gasket is provided around the perimeter of unit top. Carefully set plenum. Attach with mounting hardware provided with the plenum.

Location/Service Access

For good installation, service and maintenance access the following recommended clearances should be followed. Minimum clearances required by local, state, or federal codes, such as the NEC take precedence over those listed below. Clearance is required to allow room for side filter access, mechanical cleaning of the condenser tubes and economizer coil, access to expansion valves and other control components and to allow for possible fan shaft or compressor removal.

Unit front - 42" Unit rear - 24"

Motor location side - 36" Piping location side - 36"

Side without motor or piping -24"

Figure1. Recommended Service and Maintenance

Clearance

Airflow

24"

Do not attempt to install dollies in the center of the unit.

CAUTION

Units must not be moved in an upended position.

Floor surfaces must be protected when equipment is moved across finished flooring. Plywood sheeting may be used to protect surfaces and distribute weight loading.

Vibration Isolators

All units are provided with 1” neoprene isolation pads, shipped separately. Pads are to be installed beneath the unit and located at each corner and the center of each base channel. For units provided with more than six (6) isolator pads, evenly space the additional pads under the front and rear base channels.

Setting Factory Supplied Plenum

If the unit is provided with a factory plenum for field mounting, a forklift, slings or other suitable lifting means is

Evapora tor C oil

24"

36"

Compressors

35642

VFD

42"

36"

Removal of Shipping Restraints

Mechanical restraints are used to secure the spring mounted fan during shipment. Restraints and shipping blocks must be removed after unit has been set in its final location.

4 IM708

Refrigerant Piping

Pressure Relief Valves

All units have individual condensers per refrigerant circuit and each condenser is provided with a spring loaded relief valve. The valve is set to open when refrigerant pressure reaches 400 psig. The relief valve will accommodate a 1/2"

flare connection for applications where it is necessary to connect vent piping and run it outside the building.

CAUTION

When refrigerant is vented to the outside of the building, the vent piping should be installed as recommended in ASHRAE Standard 15-1994.

IM708 5

W ater Connections

General

Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities. They can supply the installer with the proper building and safety codes required for a safe and proper installation.

The piping should be installed with a minimum number of bends and elevation changes for best performance. Piping should contain:

1. Vibration eliminators to reduce vibration and noise transmission to the building.

2. Shutoff valves to isolate the unit from the piping system during unit servicing.

3. Manual or automatic air vent valves at the high points of the system.

4. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve).

5. Temperature and pressure indicators located at the unit to aid in servicing.

6. A strainer or some means of removing foreign matter from the water before it enters the pump. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and help maintain system performance.

7. Size piping to minimize system pressure drop.

mizer will typically elevate the water temperature by 5 to 10°F before entering the condenser, allowing suitable condenser water temperatures whenever the tower supply temperature is 50°F or higher. Mechanical cooling is locked out below 55°F EWT.

6. Head pressure control must be provided if entering condenser water temperatures will go below 55°F. Fan cycling and/or modulating discharge dampers on the cooling tower are often used, or a 3-way bypass around the tower to maintain condenser water temperature. Cooling tower control to maintain the temperature at >55°F is generally more cost effective if multiple units are in the loop. If valves are installed on the individual SWP units, a single water regulating valve controlled by circuit #1 head pressure should be used. The Lead/Lag option needs to equal “NO”. When Lead/Lag equals “NO” circuit #1 is always first on and last off. The refrigerant pressure line from the valve should be connected to a gauge port on any liquid line service valve located in the compressor #1 refrigerant circuit. Compressor #1 is located at the far left of the cabinet.

If the water regulating valve is placed in service with the

unit condensers, it should be installed in the water line leaving the condenser and should shut down to prevent water from siphoning out of the condensers. For systems where a constant pumping head is required, the water regulating valve may be installed in a bypass line around the condensers. It must then open on falling discharge pressu re.

Condenser Piping

1. Units may be specified with water and condensate connections on either the left or right side of the unit.

2. All units have an individual condenser per refrigerant

circuit. All condensers are factory piped for a common condenser water supply and a common condenser water return connection.

3. Field piping connections are made to factory provided

piping located as indicated on the unit submittal drawings. The piping connections are run to the outside of the unit cabinet. Connections are located behind a factory mounted shipping cover. All connections are copper sweat connections as indicated on unit dimensional drawings.

4. Supply and return water connections must be made at the proper locations as indicated by the dimensional drawings. Supply (water in) connection is always the lower connection.

5. Units with factory mounted water side economizer

should not require head pressure control. The econo-

These typical systems, depending on the specific application, must maintain a constant condensing pressure regardless of temperature conditions and must assure adequate head pressure for proper thermal expansion valve operation. A minimum head pressure of 180 psi (95°F condensing temperature) is recommended.

7. Condenser tube velocities must not exceed 10 feet per

second.

Figure2. Condenser Regulating Valve (refrigerant

pressure controlled

)

6 IM708

Figure3. Condenser water pressure drop SWP018 -

SWP040

24 HP

28 HP

12 HP

18 HP

32 HP

36 HP

40 HP

Figure5. Economizer water pressure drop, SPW018-

SPW105

035-040

045-095

105

018-028

Pressure Drop (ft H

60 80

Condenser Flow Rate (gpm)

100

200 300

Note: HP = total unit compressor horsepower.

Figure4. Condenser water pressure drop SWP045 -

SWP105

Pressure Drop (ft H

8 6

40HP

46HP

52HP

56HP

60HP

70HP

80HP

78HP

84HP 90HP

105HP 120HP

Pressure Drop (ft H

Note:

Condenser Flow Rate (gpm)

Includes coil, control valves and interconnecting

100 500

piping.

Add this∆P to condenser ∆P to obtain unit ∆P

for pump selection.

Figure6. Water regulating valve pressure drop.

Head pressure control

018-040

80 100

200 300

Condenser Flow Rate (gpm)

Note: HP = total unit compressor horsepower.

IM708 7

400 500

Pressure Drop (ft H

0.1

045-095

100

500

Condenser Flow Rate (gpm)

Figure7. Hot water coil pressure drop, SWP018 -

SWP040

100

018

035

023-028

040

Pressure Drop (ft H

100

Water Flow Rate (gpm)

Hot water coil pressure drop, SWP045 - SWP105

100

Condensate Drain Connection

The condensate drain connection is 1 1/8" O.D.S. copper and is located on the same end of the unit as the condenser water connections. The drain is internally trapped at the factory requiring no external trap. The condensate line should be pitched away from the unit with a minimum slope of 1/8" per foot.

Drain pans and the drain trap should be kept clean by periodic cleaning. A cleanout is provided as standard in the trap to aid in cleaning.

200

Pressur e Drop (ft H

10 100

Water Flow Rate (gpm)

055

045

065-095

105

200

8 IM708

Duct Connections

Supply Air

For connection of supply ductwork directly to the unit, a duct collar must first be mounted at the fan outlet, avoiding the mounting screws located around the perimeter of the fan discharge opening (see Figure 8). Fan discharge opening sizes are indicated on the unit dimensional drawings. When connecting ductwork to the unit, a canvas type connecting collar is recommended.

Units are available in two fan configurations and should be ducted as shown in Figure 9. Duct take-offs which go opposite to the direction of fan rotati on will result in an associated system effect loss and reduced fan performance.

If a field fabricated plenum is used, duct take-off locations should again be correctly oriented to the rotation of the fan to minimize system losses. Refer to unit dimensional drawings and Figure 8 for plenum mounting size requirements. Canvas type connectors are recommended at the duct connection to the plenum.

Units are also available with a factory provided discharge plenum. Supply duct connections to the plenum opening(s) should include a canvas type connector. Plenum opening sizes and locations will be indicated on the job submittal.

Figure8. Unit top detail

Figure9. Discharge duct configurations

Return Air

Return air to the unit can be arranged in two ways.

1. Ducted return

Return ductwork may be attached to the 2" flange around the perimeter of the unit's return air opening (Refer to Figure

10). A canvas type duct connecting collar is recommended. All ductwork connected to the unit should be of adequate size and construction for the application. A canvas type connector is also recommended where the duct penetrates the machine room wall(s). This will prevent vibration generated by air movement in the duct from being transmitted out to the occupied spaces.

Note: Do not obstruct unit access panel located below the

return opening.

2. Free return

The mechanical equipment room may be used as a return plenum with no hard connection at the unit.

Note: Some building codes do not allow the use of the

mechanical room as a return plenum. Applicable local codes should be checked for each installation.

Figure10.Back Elevation

(Optional) Multi-Directional Plenum

29”

K x L

Return Air Opening

Mechanical Access

(See Notes)

2.0” Typical

2.0”

1” Neoprene Isolation Pads, Shipped Separately

B25

IM708 9

Physical Data

Table 2: SWP 018 Through SWP 105

Data

Compressor Quantity 2, 3, 4 3, 4 4 4 4 4 4 4 4 4 4, 6 6 Size See Unit Data Plate Evaporator Coil

Face Area (Ft.2) Rows 4, 6 4, 6 4, 6 4, 6 4, 6 4, 6 6 6 6 6 6 6 Fpi 12 12 12 12 12 12 12 12 12 12 12 12 Waterside Economizer Coil

Face Area (Ft.2) Rows 4444 4 4 4 4 4 4 4 4 Fpi 12 12 12 12 12 12 12 12 12 12 12 12 Maximum Working Pressure

(psig) Hot Water Heating Coil

Face Area (Ft.2) Rows 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1 1 1 Fpi 12 12 12 12 12 12 12 12 12 12 12 12 Electric Heat Kw 34 34 34 34 34 68 68 68 68 68 68 68 Filters

(Quantity) Size 4” Depth

Evaporator Fan Quantity 1111 1 1 1 1 1 1 1 1 Size 15 18 18 20 20 22 25 25 25 27 27 33 Minimum Horsepower 5 7.5 10 10 15 15 20 20 20 25 30 40 Maximum Horsepower 10 15 20 20 25 30 40 40 40 50 60 60 Minimum Design cfm, CV 2950 3825 4425 5825 6925 7675 9025 10375 11575 12775 13975 15800 Minimum Design cfm, VAV 4720 6120 7080 9320 11080 12280 14440 16600 18520 20440 22360 25280 Maximum Design cfm 7080 9180 10620 13980 16620 18420 21660 24900 27780 30660 33540 37920 Condenser Quantity 2, 3, 4 3, 4 4 4 4 4 4 4 4 4 4, 6 6 Waterside Working Pressure

(psig) Minimum Entering

Temperature (F) Minimum GPM 25 41 53 66 69 94 105 105 121 134 138 180 Maximum GPM 88 108 125 159 166 215 237 237 251 349 358 493

a. Standard fan TSP limit is 5.5 inch of water. Consult your local McQuay sales representative for applications beyond this range.

018 023 028 035 040 045 055 065 070 080 095 105

11.8 15.3 17.7 23.3 27.7 30.7 36.1 41.5 46.3 51.1 55.9 63.2

400 400 400 400 400 400 400 400 400 400 400 400

9.3 12.8 15.2 20.2 24.5 26.8 30.4 35.8 39.9 44.4 48.3 51.9

(6)20x20x4 (2)25x20x4

400 400 400 400 400 400 400 400 400 400 400 400

55° 55° 55° 55° 55° 55° 55° 55 55° 55° 55° 55°

(6)20x20x4 (2)25x20x4

(10)25x20x4 (10)25x20x4 (12)25x20x4 (12)25x20x4 (18) 20x20x4 (6)16x20x4

SWP Model Size

(12)25x20x4

(3)20x20x4 (15)25x20x4

(6)16x20x4 (15)25x20x4

(4)16x20x4 (17)20x25x4 (1)16x25x4

Table 3: Compressor circuit charge

COMPRESSOR

(HP)

69 lbs.66 10 14 lbs. 112 13 18 lbs. 128 15 22 lbs. 256 20 27 lbs. 256

*Charge quantities listed are average. Actual cha rg e qu an tity is dependent on

individual unit evaporator coil circu iting. Actual char ge quantities are st amped on each unit nameplate.

10 IM708

*REFRIGERANT

CHARGE PER

CIRCUIT (R-22)

OIL CHARGE PER CIRCUIT

(OZ.)

Dimensional Data

Figure 1 1. Left Side Front (CW) Disch arge with 0ptional Multi-Directional Plenum

(Optional)

Multi-Directional

Plenum

(See Notes)

K x L Return Air

3.25”

19.0"

14.75”

8.75”

Filter Section

Outlet

Inlet

Heater

Evaporator

Economizer

Electrical Panel

A21

Figure 12. Left Side Back (CCW) Discharge with 0ptional Multi-Directional Plenum

9.63"

(18-95)

10.31

(Optional)

Multi-Directional

Plenum

(See Notes)

K x L Return Air

3.25”

19.0"

14.75”

Heater

Evaporator

Economizer

Filter Section

Outlet

Inlet

8.75”

(105)

Electrical Panel

A22

Note: Select unit arrangement on the unit selection.

Plenum can be shipped separately. Please indicate on the unit submittal. Indicate size and location of plenum openings on the unit submittal. All openings are on plenum centerline. For additional information refer to plenum certified drawing .

Table 4:

BASIC UNIT 018 023 028 035 040 045 055 065 070 080 095 105

A B

D FFan Disch. 18.62 21.88 21.88 24.75 24.75 27.25 31.25 31.25 31.25 34.25 34.25 47.25

G Fan Disch. ^ Opening 15.88 18.88 18.88 24.75 24.75 27.25 31.25 31.25 31.25 34.25 34.25 34.94

H Fan Disch. Location 32.69 31.06 31.06 37.62 37.62 46.38 44.38 44.38 50.38 54.88 60.88 54.40 J Fan Disch. Location 22.50 18.81 18.81 20.12 20.12 21.06 21.32 21.32 21.32 23.82 23.82 33.46 K Return Opening Height 41.44 41.44 41.44 51.44 51.44 51.44 51.44 62.20 62.20 62.20 62.20 70.20 L Return Opening Length 80.00 80.00 80.00 96.00 96.00 116.00 116.00 116.00 128.00 140.00 152.00 152.00

M Base of Return Opening 28.62 28.62 28.62 28.62 28.62 28.62 28.62 23.87 23.87 23.87 23.87 23.87

N Water Out/In (ODS) 2-1/8 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8 3-1/8 3-1/8 3-1/8 3-1/8 3-1/8 3-1/8 P 1 Row HW Donn (ODS) 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 P 2 Row HW Conn (ODS) 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-1/8 - - -

Deptha

Lengtha

Heighta

a. Dimensions do not include handle, latch or fastener extensions. b. For shipping dimensions add 4" (102mm) to depth, 8" (204mm) to length, and 4" (102mm) to height.

72.00 72.00 72.00 72.00 72.00 81.00 81.00 81.00 81.00 84.00 84.00 96.00

84.00 84.00 84.00 100.00 100.00 120.00 120.00 120.00 132.00 144.00 156.00 156.00

82.00 82.00 82.00 82.00 82.00 82.00 82.00 88.00 88.00 88.00 88.00 96.00

IM708 11

Figure 13. Unit Front Plan

Return Air

Left Side

Piping Connections

(See Notes)

Figure 14. Front Elevation

ASD (Optio nal)

MicroT ech II Panel

Supply Fan Motor

Disconnect Switch (Optional)

Power Entry 7/8" Pilot K.O.

Electrical Access

(Optional) Right Side Piping Connections (See Notes)

A23

72"

Figure 16. Left Side

K x L Return Air

1-1/8” ODS Drain

(N) W a te r O ut

(N) W ater In

Lifting Lug

1” Typ.

A/2

Figure 17. Discharge Plenum (Optional)

Plan View

Depth

Multi-Directional

(Optional)

Plenum (See Notes, Page 11)

(P) Ho t W a te r O u t

(P) Ho t W a te r In

44.5”

38.5”

Mechanical Access

Note: Service connections determined when facing the front of the

unit. Left-hand standard, right-hand optional. Please indicate on the unit submittal.

Note: Unit sizes 018, 023 and 028 have a single mechanical access

panel in bottom front and bottom back.

Figure 15. Back Elevation

H H

29”

Mechanical (See Notes)

K x L

Return Air O pening

Access

Multi-Directional Plenum (See Notes, Page 11)

2.0” Typical

2.0”

1” Neoprene Isolation Pads, Shipped Separately

(Optional)

Length

29”

Front/Back Elevation

3”

2” Min

29”

Left/Right Elevation

Table 5. Discharge Plenum

Unit Size Length (in.) Depth (in.) Height (in.) 018D-028D 84 72 29 035D-040D 100 72 29 045D-065D 120 81 29

070D 132 81 29 080D 144 84 29

095D-105D 156 84 29

3”

A27

2” Min

12 IM708

Unit Weights

Table 6. Unit and Component Weight in lbs.

Unit Weights

Basic Configuration SWP basic unit

Filters

4" 30% or 65% efficiency 38 38 38 55 55 66 66 79 87 96 104 112

Evaporator Coil

6 Row, 12 fpi 250 294 321 417 468 506 577 642 693 755 819 926 4 Row, 12 fpi 206238257333368395------

Water Economizer Coil

4 Row, 12 fpi 306 338 357 458 493 520 598 648 678 723 820 927 Water weight 51 66 75 94 111 119 150 168 187 203 218 281

Hot Water Coil

1 Row, 12 fpi 71 97 114 130 158 160 170 200 328 337 345 371 Water weight 16 20 23 28 32 37 41 49 55 59 62 62

Electric Heat

34 KW 2020202020------68 KW -----40404040404040

Supply Fan Motors

3 HP ODP 71------ ---5 HP ODP 82------ ----

7.5 HP ODP 124124----- -- -10 HP ODP 144 144 144 144 - - - - - - 15 HP ODP - 185 185 185 185 185 - - - - 20 HP ODP - - 214 214 214 214 214 214 214 - - 25 HP ODP - - - - 266 266 266 266 266 266 - 30 HP ODP - - - - - 310 310 310 310 310 310 40 HP ODP ------404404404404404404 50 HP ODP ------- -452452452 60 HP ODP ------- --620620 75 HP ODP ------- ---836 3 HP TEFC 72------ ---5 HP TEFC 85------ ----

7.5 HP TEFC 140140----- ---10 HP TEFC 170 170 170 170 - - - - - - 15 HP TEFC - 235 235 235 235 235 - - - - 20 HP TEFC - - 300 300 300 300 300 300 300 - - 25 HP TEFC - - - - 330 330 330 330 330 330 - 30 HP TEFC - - - - - 390 390 390 390 390 390 40 HP TEFC ------510510510510510510 50 HP TEFC ------- -570570570 60 HP TEFC ------- --850850 75 HP TEFC ------- ---900

Compressor/Condens e r As sembly

(2)6HP 26 368------ ---(3)6HP 35 538538----- ---(4)6HP 43 699 699 699 699 - - - - - - (3)6HP, (1)10HP 57 - 843 843 843 843 - - - - - (2)6HP, (2)10HP 66 - - 974 974 974 - - - - - (1)6HP, (3)10HP 74 - - - 1115 1115 - - - - - (4)10HP 95 - - - 1263 1263 1263 1263 1263 - - - (2)10HP, (2)13HP 106 - - - - - 1404 1404 1404 - - - (4)13HP 118 - - - - - 1549 1549 1549 1549 - - (2)13HP, (2)15HP 129 - - - - - 1709 1709 1709 1709 1709 1709 (4)15HP 141 - - - - - 1867 1867 1867 1867 1867 1867 (2)15HP, (2)20HP 152 -------198219821982 1982 (4)20HP 190 ------- -2096 2096 (6)13HP 167 ------- --22652265 (3)13HP, (3)15HP 178 ------- --24792479 (6)15HP 188 ------- --26932693 (3)15HP, (3)20HP 209 ------- --29142914 (6)20HP 229 ------- --31353135

Discharge Plenum

Factory Installed, 29” 636 636 636 711 711 862 862 862 922 1003 1064 1064

a. Base Weight includes supply fan without motor. b. Water economizer weight includes valves and piping. c. The values in this table do not include water weight.

d. Hot water coil weight includes valve and piping.

b c

Water Weight

018 023 028 035 040 045 055 065 070 080 095 105

2226 2313 2318 2638 2643 3110 3279 3406 3734 4021 4246 4673

Unit Size

IM708 13

Field Wiring

General

Wiring must comply with all applicable codes and ordinances. Warranty is voided if wiring is not in accordance with specifications. An open fuse indicates a short, ground or overload. Before replacing a fuse or restarting a compressor or fan motor, the trouble must be found and corrected. Copper wire is recommended for all power lead terminations. Contact factory for information concerning aluminum wire power lead terminations.

A single power terminal block is provided as standard and wiring within the unit is done in accordance with the National Electric Code. All branch circuits within the control panel are individually fused. A single field supplied disconnect is required or a unit mounted nonfused disconnect can be ordered with the unit.

A 7/8” knockout is located on the right-hand unit upright for locating unit power entry. 24V field connections are suitable for Class II wiring.

Unit Disconnect

Disconnecting means are addressed by Article 440 of the National Electric Code (NEC) which requires 'disconnecting means capable of disconnecting air conditioning and refrigerant equipment including motor-compressors, and controllers, from the circuit feeder." The disconnect switch should be selected and located within the NEC guidelines. Location requirements per NEC are that the disconnect be located in a readily accessible position within sight (50 feet) of the unit.

A factory mounted nonfused disconnect is available.

Table 7. Compressor Motors

Compressor

6 10 13 15 20

208/60/3 230/60/3 400/50/3 460/60/3 575/60/3

RLA LRA RLA LRA RLA LRA RLA LRA RLA LRA

17.9 156.0 16.2 156.0 8.1 70.0 8.1 70.0 6.5 54.0

31.2 239.0 28.2 239.0 14.1 125.0 14.1 125.0 11.3 80.0

35.6 350.0 32.0 350.0 16.0 158.0 16.0 158.0 12.8 125.0

42.1 425.0 38.0 425.0 19.0 187.0 19.0 187.0 15.2 148.0

74.0 360.0 67.2 360.0 33.6 180.0 33.6 180.0 36.9 144.0

Return Air and Outside Air Sensors

All units are provided with a return air sensor. The outside air sensor is optional and can be ordered with the unit. The return air sensor is connected to the input control board and is coiled up and placed in the control box of the unit for shipment. The return air sensor must be field installed in the return air stream for proper unit operation. The outside air sensor is shipped loose in a package and is located on the floor of the fan section. The mixed air temperature sensor is already installed at the inlet of the unit.

The sensors must be mounted in areas that are exposed to representative temperature conditions. The sensor should be mounted at a position that has good air mixing and does not have stratification. The sensor can be mounted in the ductwork using a grommet, see Figure 18.

Figure 18. Return/Outside Air Sensor Mounting

Sensor

Ductwork

The return air sensor is connected to the unit’s input board at location AI4, see IM710. The outside air sensor is field wired to terminal strip TB2. The sensor is to be connected at terminals 124 and 125.

Grommet

Table 8. Electric Heaters

SWP UNIT SIZE

018 - 040

045 - 105

14 IM708

208V/60HZ/3PH 230V/60HZ/3PH 400V/50HZ/3PH 460V/60HZ/3PH 575V/60HZ/3PH

kW MBH FLA kW MBH FLA kW MBH FLA kW MBH FLA kW MBH FLA

27.8 94 77.2 34 116 85.6 25.7 88 37.2 34 116 42.8 34 116 34.2

55.6 190 154.4 68 232 170.9 51.4 175 74.4 68 232 85.6 68 232 68.4

Table 9. SAF Motor Nameplate Amp Table

Horsepower TYPE

7.5

a. 460/60/3 motors are used. Derate nameplate horsepower to 0.83 to obtain actual horsepower.

High Efficiency 9.9 9.0 4.5 4.5 3.4 Premium Efficiency 9.3 8.2 4.1 4.1 3.1 High Efficiency 14.8 14.0 7.0 7.0 5.3 Premium Efficiency 15.7 13.6 6.8 6.8 5.2 High Efficiency 22.3 21.6 10.8 10.8 8.2 Premium Efficiency 22.3 20.0 10.0 10.0 7.4 High Efficiency 29.7 28.0 14.0 14.0 11.0 Premium Efficiency 29.0 25.8 12.9 12.9 10.3 High Efficiency 44.4 40.6 20.3 20.3 16.2 Premium Efficiency 43.4 37.8 18.9 18.9 14.1 High Efficiency 57.0 50.0 25.0 25.0 20.0 Premium Efficiency 57.0 49.0 24.5 24.5 18.9 High Efficiency 69.8 62.0 31.0 31.0 24.3 Premium Efficiency 70.5 61.0 30.5 30.5 24.2 High Efficiency 86.5 75.0 37.5 37.5 30.0 Premium Efficiency 83.3 72.4 36.2 36.2 29.8 High Efficiency 117.0 102.0 51.0 51.0 40.0 Premium Efficiency 110.0 96.0 48.0 48.0 38.0 High Efficiency 138.0 124.0 62.0 62.0 49.2 Premium Efficiency 137.0 120.0 60.0 60.0 47.5 High Efficiency 154.0 144.0 72.0 72.0 57.4 Premium Efficiency 159.0 140.0 70.0 70.0 56.0 High Efficiency 189.0 176.0 88.0 88.0 71.0 Premium Efficiency 195.0 170.0 85.0 85.0 65.5

208/60/3 230/60/3

FLA FLA FLA FLA FLA

400/50/3

460/60/3 575/60/3

IM708 15

Supply Power Wiring

1. Units require three-phase power supply.

2. Allowable voltage tolerances: a. 60 Hertz

Nameplate 208V: Min.187V, Max. 229V Nameplate 230V: Min.207V, Max. 253V Nameplate 460V: Min.414V, Max. 506V Nameplate 575V: Min.518V, Max. 632V

b. 50 Hertz

Nameplate 400V: Min. 342V, Max. 418V

3. Power lead wire sizing: a. For units with cooling capability (all concurrent loads)

with or without hot water heating and circuits with motor loads only:

MCA = 1.25 (largest motor RLA or FLA) + other loads + 2 amps.

b. For units with cooling capability and nonconcurrent

electric heat capability:

Lug Sizes For Single Disconnect or Power Block

Table 10. Single Disconnect

UNIT VOLTAGE SIZE (AMPS) 018-028 018-028 018-028 035-040 035-040

035 040 045 045

045 055-070 055-070 055-070 080-095 080-095 080-095

095-105 (6 Comp) 095-105 (6 Comp) 095-105 (6 Comp)

a. Disconnect is 250 amps with electric heat.

Table 11. Lug Sizes For Single Disconnect

208/230 225 400/460 100 575 100 208/230 225 400/460 150 575 100 575 150 208/230 400 400/460 575 150 208/230 400 400/460 250 575 150 208/230 600 400/460 250 575 250 208/230 N/A 400/460 250 575 250

150

In the cooling mode, the loads will be composed of supply fan motor and compressors. In heating mode, the loads will be composed of supply fan motor and electric heater. The MCA is calculated for unit running in either mode; the highest value obtained is used for the MCA.

(1)For unit in cooling mode: MCA = 1.25 (largest RLA or FLA) + other loads + 2

amps.

(2)For unit in heating mode:

MCA = 1.25 (electric heat FLA + Fan FLA) + 2 amps.

4. Size wires in accordance with T able 310-16 or 310-19 of the National Electrical Code.

5. Wires should be sized for a maximum of 3% voltage drop.

DISCONNECT SIZE LUG SIZE

100 150 225 250 400 600

#6-2/0 #2-3/0 #3-300 MCM #4-350 MCM 250 MCM-500 MCM 250 MCM-350 MCM

Table 12. Lug Sizes For Power Block

UNIT VOLTAGE LUG SIZE 018-045 055-105 055-105

Note: Use copper wire only.

ALL #6-400 MCM 400/460/575 #6-400 MCM 208/230 1/0-600 MCM

16 IM708

Control Center

All electrical controls are enclosed in a central control center located at the front of the unit. The control center is divided into two separate compartments, high and low voltage. The lower compartment houses the high voltage components and can be accessed through the “Electrical Access" panels indicated on the dimensional drawing. Behind these access panels are hinged dead front panels for further operator safety. High voltage components include:

1. Fan Motor Contactor, M30

2. Fan Motor Overload, OL10

3. Fan Motor Fuse, FB10

4. Compressor Contactors, M1-M6

5. Compressor Fuses, FB1-FB6

6. Electric Heat Contactors, M11-M16

7. Transformer, T1, T2, T3

8. Disconnect Switch, DS1-DS2

9. Power Block, PB1-PB2

Figure 19. Typical Control Center Layout High and Low Voltage Compartments

LonMark Communication Card

BACNet Communication Card

If the optional disconnect switch is provided, the switch handle is visible and accessible without removing any safety or access panels.

Low voltage components are located in the upper left compartment, and include:

1. MicroTech II Main Control Board, MCB

2. Duct Static Pressure Sensor, SPS1

3. Optional 2nd Duct Static Pressure Sensor, SPS2

4. Optional BACNet Ethernet Communication Card,

5. Optional BACNet MSTP Communication Card,

6. Optional LonMark Communicati on Card,

7. Compressor Control Board, CCB #1

8. Compressor Control Board, CCB #2 (6 compressor units only)

Located on the face of the unit is the interactive MicroTech II keypad/display, unit switch, system indicator light and power indicator.

Note: IM710 has additional layout of the control center.

Phase Voltage Monitor

Power Block

Disconnect Switch (Optional)

Adjustable Frequency Drive (Optional)

IM708 17

Transformer, Control Output, 24V, T3

Transformer, Control Output, 24V, T2

Duct Static Pressure Sensor

Transformer, Main Control, 115V, T1

Electrical Legend

Designation Description Standard Location Designation Description Standard Location

ACT1 ACTUATOR,VARIABLE INLET VANES SUPPLY FAN SEC-

ACT2 ACTUAT OR,BYPASS VALVE CONDENSER VALVE OAT OUTSIDE AIR TEMP. SENSOR EXTERNAL ACT3 ACTUATOR,WATERSIDE ECONOMIZER WATERSIDE ECONO

AFD10 ADJUST.FREQUENCY DRIVE--SUPPLY FAN MAIN CONTROL PB1 POWE R BL OCK--TOTAL UNIT OR

CCB1,2 COMPR CONTROL BOARDS--REFRIG. CIR-

CUITS

COMPR#1-6 COMPRESSORS #1--6 COMPRESSOR SEC-

DAT DISCHARGE AIR TEMP. SENSOR NEAR FAN INLET PC7 PRESSURE CONTROL--PROOF AIRFLOW FAN SECTION DHL DUCT HI-LIMIT FAN SECTION PM1 PHONE MODEM MAIN CONTROL DS1 DISCONNECT--TOTAL UNIT OR COND/HEAT MAIN CONTROL PSR1,2 PRESSURE SENSOR,REFRIGERANT LIQ. SHUTOFF

DS2 DISCONNECT--SAF/RAF/CONTROLS MAIN CONTROL PVM1 PHASE VOLTAGE MONITOR MAIN CONTROL EWT ENT. COND. WATER SENSOR COND. WATER INLET PVM2 PHASE VOLTAGE MONITOR MAIN CONTROL F1 FUS E--CONTROL CIRCUIT MAIN CONTROL R11 RELAY--ELECTRIC HEAT STAGE 1 HW/S

FB10 FUSEBLOCK--SUPPLY FAN MAIN CONTROL R12 RELAY--ELECTRIC HEAT STAGE 2 HW/S

FB11,12 FUSEBLOCKS--ELECTRIC HEAT MAIN CONTROL R1-6 RELAYS--HI-PRESSURE MAIN CONTROL FB1--6 FUSEBLOCKS--COMPRESSOR #1-6 MAIN CONTROL R18 RELAY--COOL ENABLE MAIN CONTROL FB8 FUSEBLOCK--MAIN TRANSFORMER MAIN CONTROL R67 RELAY--ENABLE SUPPLY FAN MAIN CONTROL FP1-6 FROST PROTECTION--REFRIG. CIRCUITS EVAP. COIL RAE RETURN AIR ENTHALPY EXTERNAL FS1 FREEZESTAT CONTROL BT/DT COIL RAT RETURN AIR TEMP. SENSOR EXTERNAL GRD GROUND ALL CONTROL BOX S1 SWITCH--SYSTEM ON/OFF MAIN CONTROL HL13-14 HI-LIMITS, PWR, ELEC HEATERS ELECTRIC HEAT

HP1-6 HI-PRESSURE CONTROLS, REFRIG ON COMPRESSORS

HTR-11,12 ELECTRIC HEATERS DX COIL S8 SWITCH--COOL ENABLE MAIN CONTROL HTR-15,16 ELECTRIC HEATERS DX COIL S9 SWITCH--HEAT MAIN CONTROL HTR1-6 CRANKCASE HEATERS ON COMPRESSORS

HUM1 HUMIDSTAT SENSOR EXTERNAL SD2 SMOKE DETECTOR--RETURN FAN EXTERNAL LP1-6 LO-PRESSURE CONTROLS, REFRIG ON COMPRESSORS

LWT LEAVING COND. WATER SENSOR COND. WATER OUT-

M10 CONTACTOR--SUPPLY FAN MAIN CONTROL T2 TRANSFORMER--CONTROL INPUT 24V MAIN CONTROL M11,12 CONTACTORS--ELECTRIC HEAT CONTROL M AIN CONTROL T3 TRANSFORMER--CONTROL OUTPUT 24V MAIN CONTROL M13,14 CONTACTORS--ELECTRIC HEAT SAFETY MAIN CONTROL TB10 TERMINAL BLOCK-- MAIN CONTROL M15,16 CONTACTORS--ELECTRIC HEAT CONTROL MAIN CONTROL TB2 TERMINAL BLOCK--24V-FACTORY/FIELD MAIN CONTROL M1-6 CONTACTORS--COMPR#1-6 MAIN CONTROL TB3 TERMINAL BLOCK--24V- MAIN CONTROL M17,18 CONTACTORS--ELECTRIC HEAT SAFETY MAIN CONTROL TB4 TERMINAL BLOCK--24V-COMPRESSOR MAIN CONTROL M30 CONTACTOR--INVERTER BYPASS MAIN CONTROL TB5 TERMINAL BLOCK--115V-FACTORY/FIELD MAIN CONTROL MAT MIXED AIR TEMP SENSOR BEHIND FILTERS TB6 TERMINAL BLOCK--115V/24V FACTORY MAIN CONTROL MCB1 MICROPROCESSOR CIRCUIT BOARD #1 MAIN CONTROL TB8 TERMINAL BLOCK-- MAIN CONTROL MJ MECHANICAL JUMPERS ON TEMINAL

MP1-6 MOTOR PROTECTOR--COMPR#1-6 ON COMPRESSORS

NB1 NEUTRAL BLOCKS MAIN CONTROL WF1 CONDENSER WATER FLOW SWITCH NEAR CONDENSER

TION

VALVE

MAIN CONTROL PB2 POWER BLOCK--SAF/RAF/CONTROLS MAIN CONTROL

TION

JCT.BOX

#1-6

LET

BLOCKS

#1-6

OAE OUTSIDE AIR ENTHALPY EXTERNAL

OL10 OVERLOAD RELAY--SUPPLY FAN MAIN CONTROL

COMPR/HEAT

PC5 PRESSURE CONTROL--CLOGGED FILTER FAN SECTION

OPEN

S4,5 SWITCHES--INVERTER BYPASS MAIN CONTROL

S7 SWITCH--LOCAL ON/OFF TO CONTROLLER MAIN CONTROL

SD1 SMOKE DETECTOR--SUPPLY FAN EXTERNAL

SPS1,2 STATIC PRESSURE SENSORS--DUCT/BLDG MAIN CONTROL

T1 TRANSFORMER--MAIN CONTROL

(LINE/115V)

VM1 VALVE MOTOR #1--HEATING NEAR HOT WA T ER

VM5 VALVE MOTOR #5--COOLING NEAR CHILLED

ZNT1 ZONE TEMP. SENSOR--SETBACK FIELD INSTALLED

MAIN CONTROL

VALVES

MAIN CONTROL

INLET

WATER

18 IM708

200

M/J

FIELD WIRING TERMINA L FIELD WIRING TERMINAL TERMINAL P.C. BOARD FACTORY WIRED WIRE NUMBER WIRE CONNECTOR OPTION BLOCK PLUG IN CONNECTOR

MECHANICAL JUMPER

Typical Wiring Schematics

Figure 20. Power Schematic

IM708 19

Figure 21. Input Schematic, Discharge Air Control (DAC)

20 IM708

Figure 22. Input Schematic, Zone or Space Comfort Control (SCC)

IM708 21

Figure 23. Output Schematic, Actuator Control

22 IM708

Figure 24. Output Schematic, Auxiliary Fan Start/Stop Control

IM708 23

Figure 25. Output Schematic, Actuator Control

24 IM708

Figure 26. Output Schematic, Compressor Control (4 Compressors/4, 5 or 6 Stage)

IM708 25

Figure 27. Output Schematic, Compressor Control (6 Compressors / 6 Stage)

26 IM708

Standard Controls

High Pressure Switches

The high pressure switch (HP1-HP6) is a single pole pressure activated device that opens on a pressure rise. When the switch opens it de-energizes the compressor circuit, shutting down the compressor. The MicroTech II controller will display an alarm condition. Once the cause of the fault has been identified and corrected, the unit may be manually reset through the MicroTech II keypad/display interface. The control is attached to a Shrader fitting and is located at the compressor. To check the control, shut off water flow to the condensers and observe the cutout point on a high pressure gauge. The high pressure control should open at 360 psig and close at 300 psig. After testing the high pressure control, check the pressure relief device for leaks.

Low Pressure Switches

The low pressure switch (LP1-LP6) is a single pole pressure activated device which closes on a pressure rise. It senses evaporator pressure and is factory set to close at 60 psig and open at 35 psig. Compressor operation is not allowed until the switch closes. The low pressure switch is an automatic reset control. If the condition occurs on any one compressor three times in a 24-hour period, the alarm will have to be manually reset through the MicroTech II keypad/display interface to restart the compressor. The low pressure switch is attached to a Shrader fitting and is located at the compressor.

Compressor Motor Protector

All compressors are thermally protected. All 13 horsepower and larger compressors use a solid state protection device (MP1 - MP6) located in the compressor junction box. Whenever the protection system opens the compressor is shut down for a period of 36 minutes and an alarm indication is made at the MicroTech II controller.

All 6 and 10 horsepower compressors have in-line protection. The control automatically resets when the alarm condition is removed and the time delay is satisfied.

If the condition occurs on any one compressor three times in a 24-hour period, the alarm will have to be manually reset through the MicroTech II keypad/display interface to restart the compressor.

Proof of Airflow Switch

A positive proof of airflow switch (PC7) is provided with all units. The switch is factory set to close at 0.2 inches of water column. The switch has a field adjustable set point range of

0.17 to 5.0 inches of water column. Turn adjustment screw

clockwise to decrease differential pressure setting. Turn adjustment screw counterclockwise to incre ase differential pressure setting. In a constant volume system, if the fan system is energized and the minimum pressure setting of the switch has not been reached, the unit will be shut down and a loss of airflow alarm indicated at the MicroT ech II controller . For variable air volume units, the unit will shutdown due to loss of airflow only if the airflow switch is open AND the duct static pressure is less than half the duct static pressure setpoint. Once the reason for the fault has been corrected, the unit can be manually reset through the MicroTech II keypad/display interface. PC7 is located in the fan section on the motor side.

Frost Protection Switches

A frost protection switch (FP1-FP6) is used on each refrigerant circuit to protect against evaporator coil freeze up. The frost protection switches are normally closed and open on a drop in temperature. When a frosting condition is sensed the compressor circuit is shutdown until the condition has been removed. The frost protection control is an automatic reset control. If the condition occurs on any one compressor three times in a 24 hour period, the alarm will have to be manually reset through the MicroTech II keypad/display interface to restart the compressor. The MicroTech II control wi ll in dicate a warning when a frost condition exists. The temperature sensors are located on a return bend for each refrigerant circuit.

Clogged Filter Switch

A clogged filter switch (PC5) is provided to indicate when unit filters are to be changed. The switch is factory set to close at 0.6 inches of H set point range of 0.17 to 5.0 inches of H screw clockwise to decrease differential pressure setting. Turn adjustment screw counterclockwise to increase differential pressure setting. When the filter pressure differential exceeds the switch setpoint, a clogged filter indication is made at the MicroTech II controller. The unit is allowed to continue operation. PC5 is located in the fan section on the motor side.

O. The switch has a field adjustable

O. Turn adjustment

IM708 27

Unit Options

Duct High Limit

A duct high limit (DHL) pressure control is provided as standard with all units having variable air volume control. The duct high limit is intended to protect the ductwork, etc. from over pressurization caused by tripped fire dampers or a control failure. When the duct pressure exceeds the setting of the control, the unit is de-energized via the MicroTech II controller and an alarm condition indicated. After the reason for trip has been identified and corrected, the control can be reset via the MicroTech II keypad/display interface.

The duct high limit is factory installed including sensing tubing, and preset for a 3.0" wc trip point. The control can be readjusted in the field to match the specific ductwork of a project. The switch has a field adjustable set point range of

0.17 to 5.0 inches of H2O. Turn adjustment screw clockwise to decrease differential pressure setting. Turn adjustment screw counterclockwise to increase differential pressure setting. DHL is located in the fan section on the motor side.

Phase Fail/Under Voltage Protection

The monitor is a microprocessor controlled device which provides protection against three-phase electrical motor loss due to low voltage, phase loss, voltage unbalance and phase reversal. The microprocessor constantly monitors the threephase line voltages and detects these harmful power line conditions. Whenever any of these conditions occur, the SWP controls are deactivated and remain deactivated until power line conditions return to an acceptable level. Trip and reset delays have been provided to prevent nuisance tripping due to rapid power fluctuations. The trip and reset delays are field adjustable. The monitor also provides a variable line voltage adjustment.

3. The sensing tube should be located in a nonturbulent flow area of the duct. Keep several duct widths away from take-off points, bends or neck downs.

Mounting instructions (See Figure 28)

1. Drill hole in duct at remote sensing point and install a rubber grommet. Insert sensing tube 1/8" into the duct and securely clamp tubing to the duct, being sure not to stress or kink the tubing. The end of the sensing tube must be smooth and cut straight across. An angle cut will affect operation.

2. Clamp a second tube to the outside of the duct at the location of the sensing point.

3. Run both tubes along the ductwork and back to the unit.

The tubing may be routed to the pressure sensor (SPS1) by drilling two holes through the unit upright post. A grommet must be used at each hole to protect the tubing and seal the cabinet.

Note: To avoid confusion between "high" and "low" tubing,

it is recommended that two different tubing colors be used and that this information be recorded, along with the sensing point location, on the master building blueprints.

4. Connect tubing to the high and low ports on the sensor.

Figure 28

Duct Static Pressure Sensor

All units provided with variable air volume control include a factory mounted static pressure sensor (SPS1). The unit can also have an optional second static pressure sensor, SPS2. The sensor is factory wired and requires field installation of 1/4" I.D. sensor tubing to the selected duct location.

Note: Be sure that tubing complies with local code

requirements. Flame retardant plastic or metal tubing may be required. Carefully select the ductwork sensing point for the pressure sensor. Improper location of the sensing point will result in unsatisfactory operation of the entire variable air volume system. The following guidelines should be adhered to:

1. Sense near the end of long duct runs to ensure that all terminal box take-offs along the run will have adequate static pressure to operate.

2. The end of the sensing tube must be perpendicular to the airflow in order to sense only static pressure.

28 IM708

Building Static Pressure Sensor

If a unit has direct building static pressure control capability, static pressure taps must be field installed and connected to pressure sensor SPS1 in the unit. This sensor is located on the control panel.

The two static pressure sensing taps must be carefully located and installed. Improper location or installation of the sensing taps will cause unsatisfactory operation. Following are pressure tap location and installation recommendations for both building envelope and lab, or "space within a space," pressure control applications. The installation must comply with local code requirements.

CAUTION

Condenser Water Flow Switch

Fragile sensor fittings. May damage pressure sensor.

If tubing must be removed from a pressure sensor fitting, use care. Do not wrench the tubing back and forth to remove or the fitting may break off.

Building pressurization applications

1. Install a tee fitting with a leak-tight removable cap in each tube near the sensor. This will facilitate connecting a manometer or pressure gauge if testing is required.

2. Locate the building pressure (HI) tap in the area that requires the closest control. Typically, this is a ground level floor that has doors to the outside.

3. Locate the building tap so that it is not influenced by

any source of moving air (velocity pressure). These sources may include air diffusers or outside doors.

4. Connect the tube to the 1/4 inch HI fitting on sensor SPS1. Assure that the sensor does not support the weight of the tubing; use tube clamps or some other means.

5. Locate the reference pressure (LO) tap on the roof. Keep

it away from the condenser fans, waIls, or anything else that may cause air turbulence. Mount it high enough above the roof so that it is not affected by snow. If the reference tap is not connected to the sensor, unsatisfactory operation will result.

6. Use an outdoor static pressure top (Dwyer A306 or equivalent) to minimize the adverse effects of wind. Place some type of screen over the sensor to keep out insects. Loosely packed cotton works well.

7. Route the outdoor tap tube out of the main control panel

through a small field-cut opening in the edge of the control wiring raceway cover. Cut this "mouse hole" in the vertical portion of the edge. Seal the penetration to prevent water from entering. Connect the tube to the 1/4 inch LO fitting on sensor SPS1.

Freezestat

A non-averaging type freezestat (FS1) is available to protect hydronic coils from subfreezing temperatures. If the unit has an economizer coil the control is mounted on the entering face of the economizer coil. If the unit does not have an economizer coil the control will be mounted on the leaving face of the hot water coil. Upon sensing a hazardous temperature, the unit will shutdown, open hydronic control valves and send an alarm indication via the MicroTech II controller. The freezestat has a field adjustable setpoint range of 35°F to 40°F. The setpoint may be changed by turning the adjustment screw until pointer is opposite the desired cutout point. The adjustment screw is accessible at the bottom of the control or at the top when the cover is removed.

A pressure differential type flow switch (WF1) is available to verify flow to the unit condensers before compressor operation is allowed. The flow switch is factory installed in the unit next to the condenser piping connections. If a loss of condenser water flow is sensed, the cooling will be locked out via the MicroTech II controller. When flow is restored, the unit will automatically reset.

The factory settings for the water flow switch N.O. contacts are as follows:

Unit Size Close Adj. Open Adj.

Ft. wc Range Ft. wc Range

018D-040D

045D-105D

3.0 +0.0 1.5 +0.5

-0.5 -0.5

4.5 +0.0 3.0 +0.5

-0.5 -0.5

Water Side Economizer

A completely factory installed, piped and controlled water side economizer system is available on any constant or variable air volume system. Whenever the entering water temperature is more than 3°F (adjustable at the MicroTech II keypad/display) below the mixed air temperature to the unit, the control valves modulate to provide cooling directly from the tower water. The economizer system can be used to provide 100% of the cooling demand or supplement mechanical cooling by precooling the return air. The economizer system consists of a water coil and two, two-way control valves. The unit's MicroTech II controller will modulate the control valves to satisfy the cooling demand whenever the entering water is suitable. When the control valves are in the 90% open position, the unit's compressors will be allowed to be staged on to satisfy the cooling load. When the entering water temperature is no longer suitable, the economizer control valve will close and the unit will be on 100% mechanical cooling.

Two valve control arrangements are available from the factory. The first maintains full flow through the unit condensers at all times. This control arrangement is used for systems with constant pumping systems. For installations with a variable pumping system, the control valves will be sequenced such that flow is removed from the unit whenever cooling is not required. A mechanical clutch is provided on each valve to manually close or open the valves.

The economizer system is factory piped and the coil takes advantage of the same drain pan and condensate connection. Air may be vented from the economizer coil by using the uppermost clean out plug. The torque requirement for the cleanout plugs is 10 inch-lb.

IM708 29

Condenser Water, Head Pressure Control

An optional condenser head pressure control valve is available on units without water side economizer. This option permits operation with entering water temperatures below 55°F . The valve is a two-way regulating valve controlled via MicroTech II to maintain refrigerant head pressure .

Variable Inlet Vanes

An optional variable inlet vane assembly is available for variable air volume applications. The assembly consists of inlet funnels with integral sets of lever-actuated radial vanes, one assembly for each side of the fan. The vanes, upon opening, direct air in the direction of wheel rotation.

The vanes rotate 90 degrees from closed to full open in response to the factory installed actuator motor. The actuator is controlled by the unit's MicroTech II controller. The inlet vanes operate in unison and are properly adjusted and tested before the unit leaves the factory. The start-up contractor must check the adjustments and retighten all bolts and ball joints to insure that shipping and handling has not caused misalignment.

Adjustable Frequency Drive

As an option an adjustable frequency drive (AFD), is available for airflow modulation. A manually activated bypass contactor is provided to allow system operation in the event of drive service.

Static pressure is controlled by the unit mounted MicroTech II controller. Indication of current airflow is available at the MicroTech II controller. Static pressure is sensed by one or two factory mounted duct sensors. The installer provides and

installs the sensor tubing from unit mounted sensor(s) to duct location(s). The static pressure setpoint is keypad adjustable through the MicroTech II DDC controller.

All variable air volume units include field adjustable duct high limit safety control to protect ductwork from excessive duct pressure.

Disconnect Switch

A factory mounted, nonfused main circuit interrupter for disconnecting the main electrical power is available. The switch is located at the front of the unit on the control panel and is accessible without unit penetration. The lug size information is provided in Tables 11 and 12.

Dual Power Supply

The dual power block is an option for the power supply. This allows the fan motor and control circuit to be isolated from the compressor circuit. If the unit has the optional electric heat it will be circuited with the compressors.

Electric Heat

Optional electric heat is available. Heat is controlled by the unit's MicroTech II unit controller to maintain setpoint. The

heaters are factory installed and wired including branch fusing and all safety controls.

Hot Water Control

A factory mounted, 1 or 2 row hot water coil is available, with or without factory mounted control valve. The hot water control valve is controlled by the unit's MicroTech II controller to provide morning warm-up heat or heat for constant volume application.

30 IM708

System Check, Test and Start

WARNING

Electric shock hazard. Failure to bond the frame of this equipment to the building electrical ground by use of the grounding terminal provided or other acceptable means may result in electric shock. Disconnect electric power before servicing equipment.

General

Only qualified personnel should perform the start-up and service of this equipment. A representative of the owner or the operator should be present during start-up to receive instruction in the operation, care and adjustment of the unit.

To assure proper warranty coverage, the unit must be put through a check, test and start-up procedure. The completed check test and start form (supplied with each unit) must be signed and returned to McQuay International.

Note: Always open power disconnect switch before open-

ing service panels.

Pre Start-up

1. Check that the unit is completely and properly installed with ductwork connected. Check that all construction debris is removed and filters are clean.

2. With all electrical disconnects open, check all electrical

connections to be sure they are tight. Although all factory connections are tight before shipment, some loosening may have resulted from shipping vibration.

3. Check all compressor valve connections for tightness to

avoid refrigerant loss at start-up. Although all factory connections are tight before shipment, some loosening may have resulted from shipping vibration. Refer to Table 13 for proper valve torque values.

4. Check tightness of setscrews in bearings, drives, and fan

wheels. If retightening is needed, make certain fan wheels are centered between the inlet openings and setscrews are torqued per Table 14.

5. Check that the fan rotates freely. Check belt tension and

alignment.

6. Check that the unit condenser water connections and

condensate drain connections have been made.

7. Before attempting to operate the unit, review the control

layout description to become familiar with the control locations. Review all equipment service literature and the unit wiring diagrams supplied with each unit. Review optional controls to determine which are included in the unit.

8. Make sure that the return air temperature sensor and optional space temperature sensor, if used, have been installed in the return air duct and that the wiring terminations have been made at the unit Input Board.

9. Make sure that entering and leaving condenser water

temperature sensors are mounted.

10. Make sure that the optional duct static pressure sensor is

connected to the duct with appropriate tubing. The unit may have one optional static pressure sensor, SPS1. The other option would be that or SPS1 and SPS2.

11. Check the voltage of the unit power supply and see that

it is within the ±10% tolerance that is allowed. Phase voltage unbalance must be within ±2%.

12. Check the unit power supply wiring for adequate ampacity and a minimum insulation rating of 75°C.

13. Verify that all mechanical and electrical inspections have been completed per local codes.

14. Open the compressor suction and discharge shutoff

valves until backseated. Always replace valve seal caps.

15. The following must be done only for uni ts with 20 hp compressors. Making sure unit switch S7 is in the "OFF" position, throw the main power disconnect to "ON." This will energize the crankcase heaters. Wait a minimum of 24 hours before starting up the unit.

Table 13. Valve Torques

COUPLING

NUT SIZE

INCH

1.00 7±1 32±2 55+5

1.25 7±1 32±2 90+10

1.75 7±1 45±3 205+15

GAGE PORT

CAP TORQUE

LBS-FT

STEM CAP

TORQUE

LBS-FT

COUPLING

NUT TORQUE

LBS-FT

Table 14. Setscrew Torque

SETSCREW DIAMETER TORQUE MIN. (FT.-LBS.)

#10 4.3 1/4” 10.0

5/16” 20.0

3/8” 25.0

Start-up

General

All units are factory tested to assure proper operation in the field.

1. Close disconnect switch with switch S7 in the "OFF" position. Allow crankcase heaters to operate for 24 hours.

2. Power should now be supplied to the MicroTech II controller and the LEDs on MCB1 should follow the normal startup sequence.

IM708 31

3. Set internal MicroTech II time clock or external time clock if used.

4. Set cooling setpoint to a value which will assure a full

call for cooling.

5. Start the auxiliary equipment for the installation such as

water pumps, cooling towers, etc.

Fan start-up

1. Place the unit into the "FAN ONLY" mode through the

keypad:

System summary:

Control Mode:

Off Auto Heat/Cool Heat only Cool only Fan only

2. Turn switch S7 to "ON". The supply air fan should start and run.

3. Observe fan rotation. If fan is rotating backward,

reverse two legs of the main unit supply power. Unit compressors are factory “phased” to match the supply fan. Do not reverse internal fan motor power leads as this will result in the compressor being out of phase. If fan does not run:

a. Check the control circuit fuse F1. b. Check control transformer fuse FB7. c. Verify that the fan overload is not tripped. d. Check the fan motor power fuses. e. Trace the circuits.

Compressor start-up

With the supply air fan operational, prepare for compressor operation. Note: The unit is shipped with the refrigeration service valves closed. Backseat (open) the suction, discharge and liquid line valves and replace service caps.

Connect service gauges and crack valves off the backseat position (one turn forward). Verify that the unit has not lost its refrigerant charge due to shipping damage or leaks. The 20 hp compressor have crankcase heaters that need to be verified they are operating. These should operate at least 24 hours before starting compressors.

1. Set Cooling Control Setpoint, menu 13, to a value which

will assure a call for full cooling.

2. Place unit into the “COOL ONLY” mode through key-

pad/display.

3. If desired, the MicroTech internal control timers can be reduced to 20 seconds. The amount of time it operates in this “Fast” mode can be entered through the keypad:

Setup/Service

Timer setting

Service

Note: "Fast" timers should only be used to verify

sequencing of compressors during start-up. The

timer must be returned to "Normal" for proper unit operation.

Do not allow compressors to come on repeatedly in the "Fast" timer mode as this may damage compressors and/or will indicate "Motor Protector Failure" under compressor alarms.

The compressors should now start. Start compressors one at a time, beginning with compressor number 1. Facing the unit, from left to right, compressors are numbered #1, #3, #4 and #2.

If the compressor motor hums but does not run, verify that the unit is getting three phase power.

The compressors should run continuously. If a compressor cycles on the low pressure switch: a. Verify that the circuit is not low on charge. b. Check for low airflow. c. Check for clogged filters. d. Check for restricted ductwork. e. Check for very low mixed air temperatures to the unit. f. Verify that all the distributor tubes, expansion valve and

liquid line components are feeding the evaporator coil. g. Verify that all fan section access panels are in place. h. Verify that the suction service valves and the liquid line

service valves are completely open. i. Verify that all sensor inputs are connected.

Economizer start-up

The economizer is modulated to maintain the cooling setpoint. With entering water temperature more than 3°F below the mixed air return to the unit, place the water sensor in a cold bath if supply water to the unit is too warm, and the unit calling for cooling, observe that the economizer control valve modulates open. Readjust control setting or remove the sensor from the bath and observe that the economizer control valve drives closed.

Hot water start-up

The hot water valve is modulated to maintain the discharge heating setpoint. To verify the hot water valve operation, adjust the heating setpoint through the keypad:

Temperatures

Zone heating

OCC HTG SPT

Set the heating setpoint to a temperature greater than the control temperature plus the dead band. Note the cooling setpoint must be higher than the heating setpoint. With the heating setpoint set properly the hot water valve should modulate open. T o close the hot water valve adjust the heating setpoint below the control temperature minus the dead band. After testing the hot water valve, return the heating setpoint to its proper setting.

Expansion valve superheat adjustment

It is very important that superheat is set properly. It should be between 10°F and 12°F under full load conditions. Lower entering air conditions, lower airflow rates and higher condensing temperatures reduce the load on the expansion valve. Under reduced load conditions, the superheat could be

32 IM708

as low as 6°F to 8°F. Insufficient superheat will cause liquid floodback to the compressor and possible liquid slugging. Excessive superheat will reduce system performance and shorten compressor life. Verify that the sensing bulb is properly located (see Figure 23) and securely strapped to the refrigerant line. Turn the adjusting stem clockwise to increase superheat. Adjust the stem (maximum one turn at a time) and observe the superheat. Allow up to 30 minutes for the system to rebalance at the final setting.

Refrigerant Charge

Units are shipped with a full operating charge of refrigerant and oil. However, in the event of a leak in the system, some added charge may be required. If an undercharged situation occurs, any of the following may be experienced:

1. If a circuit is slightly undercharged, bubbles will show in the sightglass.

2. If a circuit is moderately undercharged, it may trip on its

frost protection sensor.

3. If the circuit is severely undercharged, it may trip on its low pressure safety.

If any of these conditions occur, first identify and correct the source of the leak and then follow the charging procedure described below.

Using the liquid line sight-glass as the sole means of metering additional refrigerant charge into a self-contained unit, or any AC unit, will not always provide the desired result. Depending on the load conditions experienced by the equipment during the charging process, adding refrigerant until the sight-glass is clear of all bubbles may over charge the system and cause future operating issues. The better way to charge a circuit is to use liquid sub-cooling and suction line superheat as indicators, using the following procedure:

1. Verify that superheat is set per the System Check, Test

& Start procedures in this manual.

2. Measure the discharge pressure reading and convert it to a discharge temperature.

3. Measure and record the circuit's liquid line temperature.

4. Measure and record the entering condenser water tem-

perature using the MicroTech II display.

5. Calculate liquid subcooling: subcooling = discharge temperature - liquid line temperature

6. If the calculated subcooling value is less than 8ºF, refrig-

erant needs to be added.

7. Monitoring discharge pressure and liquid line temperature, add refrigerant until the discharge temperature minus the liquid line temperature is equal to 8ºF ± 2ºF. If the system is running at light load conditions, subcooling should be at the low end of the range. If the system is running near design conditions, subcooling should be near the upper end of the range.

8. Verify that superheat is still in the prescribed range. Following this method should prevent over charging of

the circuit.

Figure 29. Water and Refrigerant Piping Schematic

Note: Water Temperature Sensor to be installed by others

in field after the condenser water connections are made.

IM708 33

Variable air volume (VAV) start-up

Enter the duct static pressure setpoint value and parameters through the keypad:

Air/Water Flow

Duct static pressure

Ducts tsp SPT

When the appropriate number of VAV terminal boxes are opened by setting down there respective thermostats, the vanes should go to the maximum airflow. Upon closing enough VAV boxes by setting their respective thermostats up, the inlet vanes should go to the minimum airflow position.

Rpm changes

All units are provided with fixed pitch sheaves selected for the specified operating conditions. If a new fan rpm selection is required a new sheave selection will need to be field installed. Adjust belt tension as described below.

Drive sheave alignment and belt tension

Drive sheave alignment should be checked using the fourpoint method shown in Figure 30. When measuring from the straight edge to the belt, the dimensions A, B, C and D must be equal for correct alignment.

Check drive for adequate run-in belt tension. Use the following procedure to determine proper belt tension:

Step 1. Measure span length (t) as shown in Figure 31.

Step 2. From Figure 31, the deflection height (h) is always

1/64" per inch of span length (t). For example, a 32" span length would require a deflection of 32/64" or 1/2".

Step 3. Determine the minimum and maximum recom-

mended pounds force using Table 14. Find the minimum recommended deflection force for the belt section and type based upon the small sheave diameter. For intermediate sheave diameters and/or drive ratio combinations, the minimum force may be interpolated.

Step 4. Using a spring scale, apply a perpendicular force to

any one of the belts at the midpoint of the span as shown in Figure 31. Compare this value with the values found in Step 3.

a. If the value is below the minimum, the belts are

too loose and should be tightened.

b.If the value is higher, the belts are too tight and

tension should be decreased.

When new belts are installed, the initial tension will drop. Check tightness of all setscrews on the fan hub, bearing sleeves and retighten belts after 48 hours of operation.

Note: If after all tension adjustments, the belts slip or

squeal when starting, increase tension slightly and replace the belts if they are worn or glazed.

34 IM708

Final control settings

When all of the start-up procedures have been completed, set the individual control parameters for operation.

1. Unit switch S7 to AUTO.

2. Heating/Cooling control parameters set as required.

3. Alarm limits set as required.

4. Night setback parameters set as required.

5. Duct static pressure, building static pressure, as required.

6. Economizer control parameters set as required.

7. Control timers set as required.

8. Date and time set as required.

9. Operating schedule set as required.

10. Holiday schedule set as required.

Note: See Operation manual per Table 1 on page 3, for the

keypad menu structure.

Maintaining control parameter records

After the unit has been checked, tested and started and the final control parameters are set, the final settings should be recorded and kept on file. This file should be updated whenever changes are made to the control parameters. This will facilitate any required analysis and troubleshooting of the system operation.

Figure 30. Drive Alignment

FIELD SUPPPLIED STRAIGHTEDGE

BCD

Figure 31. Belt Tension

Table 15. Recommended Pounds Force Per Belt

BELT

SECTION

5VX

SMALL SHEAVE

DIA. (IN)

3.0 - 3.6 3.00 4.25

3.8 - 4.8 3.5 5.00

5.0 - 7.0 4.00 5.50

3.4 - 4.2 4.00 5.50

4.4 - 5.6 5.13 7.13

5.8 - 8.6 6.38 8.75

3.4 - 5.6 6.50 9.13

4.4 - 5.6 6.50 9.13

5.8 - 8.6 7.38 10.13

4.7 - 6.7 10.00 15.00

7.1 - 10.8 12.88 18.75

11.8 - 16.0 15.00 22.00

MINIMUM MAXIMUM

IM708 35

System Maintenance

WARNING

Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and are experienced with this type of equipment.

WARNING

Moving machinery and electrical power hazards. May cause severe personal injury or death.

Disconnect and lock off power before servicing equipment.

CAUTION

Sharp edges are inherent to sheet metal parts, screws, clips and similar items. May cause personal injury.

Exercise caution when servicing equipment.

Preventative Maintenance

Preventative maintenance is the best way to avoid unnecessary expense and inconvenience. Have this system inspected at regular intervals by a qualified service technician. The required frequency of inspections will depend on installation and operating duty. Routine maintenance should cover the following items:

1. Tighten all belts, setscrews, and wire connections. (See table 14, page 31.)

2. Clean evaporator or economizer coils mechanically or with cold water, if necessary. Usually any fouling is only matted on the entering air face of the coil and can be removed by brushing.

3. Clean condenser and economizer tubes on a periodic basis. Condenser and economizer coils can be cleaned chemically or mechanically . T ubing should be kept clean to maintain system performance.

4. Lubricate motor and fan shaft bearings.

5. Align or replace belts as needed.

6. Replace filters as needed.

7. Check refrigerant sightglass. Check for refrigerant leaks

if sightglass is not solid with steady-state full load operation of unit. (Note: A partially full sightglass is not uncommon at part load conditions. Check for proper superheat.)

8. Check for blockage of condensate drain. Clean conden-

sate pan as needed.

9. Check power and control voltages.

10. Check running amperage.

11. Check operating temperatures and pressures.

12. Check and adjust temperature and pressure controls.

13. Check and adjust linkages.

14. Check operation of all safety controls.

15. Lubricate door latch mechanisms.

Motor Bearings

Fan motors should have grease added after every 2,000 hours of operation. Relubricate while motor is warm and at a standstill. Remove and clean upper and lower grease plugs, insert grease fitting into upper hole adding a small amount of clean grease with a low pressure gun. Run motor for five minutes before replacing plugs.

Note: Specific greasing instructions are to be found on a

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

CAUTION

Bearing overheating potential. Can cause damage to the equipment.

Do not overlubricate. Use only a high grade mineral grease with a 200°F safe operating temperature. Refer to unit lubrication instruction label for specific lubricants

36 IM708

Replacement Parts

Description McQuay Part

Number

Zone temperature sensor with tenant override 111048101 Outside air temperature sensor 060004703 Airflow proving switch 060015801 Discharge air temperature sensor 060004702 Return air temperature sensor 060004703 Freeze stat 072502001

Filters

Unit Size Filter Size Qty

Part Number

2"-35% 4"-35% 4"-65% 4"-85%

018-028 20 x 20

20 x 25 035-040 20 x 25 10 072407704 072402304 072405704 072405704 045-055 20 x 25 12 072407704 072402304 072405704 072405704

065 20 x 20 18 072407703 072402303 072405703 072407603 070 16 x 20

20 x 25

080 20 x 20

20 x 25

095 16 x 20

20 x 25

16 x 20

105

16 x 25

20 x 25

6 2

4 1

072407703 072407704

072407701 072407704

072407703 072407704

072407701 072407704

072407701 072407702 072407704

072402303 072402304

072402301 072402304

072402303 072402304

072402301 072402304

072402301 072402302 072402304

072405703 072405704

072405701 072405704

072405703 072405704

072405701 072405704

072405701 072405702 072405704

072407603 072407604

072407601 072407604

072407603 072407604

072407601 072407604

072407601 072407602 072407604

IM708 37

Service and Warranty Procedure

In Warranty Return Material Procedure

Material may not be returned except by permission of authorized factory service personnel of McQuay International at Minneapolis, Minnesota.

A "return goods" tag will be sent to be included with the returned material. Enter the information as called for on the tag in order to expedite handling at our factories and prompt issuance of credits. All parts shall be returned to the factory designated on the return goods tag, transportation charges prepaid.

The return of the part does not constitute an order for replacement. A purchase order for the replacement part must be entered through your nearest McQuay representative. The order should include part number and description, and the model and serial numbers of the unit involved.

Following inspection of the returned part by our personnel and if it is determined that the failure is due to faulty material or workmanship, credit will be issued on customer's purchase order.

Replacement Parts

When writing to McQuay for service or replacement parts, refer to the model number, serial number, and G.O. number of the unit as stamped on the serial plate attached to the unit. For questions regarding wiring diagrams, it will be necessary to provide the number on the specific diagram. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunction and a description of the replacement parts required.

Product Warranty

McQuay International, hereinafter referred to as the "Company," warrants that it will provide, at the Company's option, either free replacement parts or free repair of component parts in the event any product manufactured by the Company and used in the United States proves defective in material or workmanship within twelve (12) months from initial start-up or eighteen (18) months from the date shipped by the Company, whichever comes first. For additional consideration, the Company warrants that for four (4) years following the

initial warranty period it will provide, at the Company's option, free replacement parts for the motor-compressor, or, free replacement for any integral component of the motorcompressor which provides defective in material or workmanship. (Extended warranties for motor-compressors are not applicable unless separately purchased.)

To obtain assistance under the parts warranty or extended motor-compressor warranty, simply contact the selling agency. To obtain information or to gain factory help, contact McQuay International, Warranty Claims Department, P. O. Box 155 1, Minneapolis, MN 55440; telephone (763) 553-5330.

This warranty constitutes the buyer's sole remedy. It is given in lieu of all other warranties. There is no implied warranty of merchantability or fitness for a particular purpose. In no event and under no circumstances shall the Company be liable for incidental or consequential damages, whether the theory be breach of this or any other warranty, negligence or strict tort.

This parts warranty and the optional extended warranties extend only to the original user. Of course, abuse, misuse, or alteration of the product in any manner voids the Company's warranty obligation. Neither the parts or extended warranty obligates the Company to pay any labor or service costs for removing or replacing parts, or any shipping charges. Refrigerant fluids, oils, and expendable items such as filters are not covered by this warranty.

The extended warranties apply only to integral components of the motor-compressor or heat exchanger, not to refrigerant controls, electrical controls, or mechanical controls, or to failures caused by failure of those controls.

Attached to this warranty is a requirement for equipment containing motor-compressors and/or furnaces to report start-up information. The registration form accompanying the product must be returned to McQuay International within ten (10) days of original equipment start-up. If that is not done, the date of shipment shall be presumed to be the date of start-up and the warranty shall expire twelve (12) months from that date.

No person (including any agent, salesman, dealer, or distributor) has authority to extend the Company's obligation beyond the terms of this express warranty, or to state that the performance of the product is other than that published by the Company.

38 IM708

Check, Test and Start Procedure Form

Compressorized Equipment Warranty Registration Form:

This form must be filled out and returned to McQuay, Warranty Department, within 10 days in order to comply with the terms of McQuay Warranty.

Check, Test and Start Procedure for SWP/SWT (Self-contained Air Conditioning Systems)

Job Name: McQuay G.O. No.:

Installation Address:

City: State:

Purchasing Contractor:

City: State:

Unit Model No.: Serial No.:

Compressor No. 1 Serial No. Compressor No. 3 Serial No. Compressor No. 4 Serial No. Compressor No. 5 Serial No. Compressor No. 6 Serial No. Mark N/A on all items not applying to the type of the unit. See IM Bulletin for more information. Any additional comments may be made on a separate sheet of paper and attached to this form.

Compressor No. 2 Serial No.

INITIAL CHECK

A. Is any shipping damage visible? Yes No B. Is unit installed level? Yes No C. Is unit positioned to provide adequate free area for service and operation? Yes No D. Are fan drives properly aligned and belts adjusted? Yes No E. Does fan turn freely? Yes No F. Tightened all setscrews on pulleys, bearings and fans? Yes No G. Have the Condenser Water Temperature Sensors been located correctly? Yes No H. Has the Installing Contractor installed the Return Air Temperature Sensor

in the Return Air stream? Yes No

I Has the Installing Contractor installed the high & low Static Pressure Sensor

tubing in the ductwork? Yes No J. Does electrical service correspond to unit nameplate? Yes No K. Adequate disconnect and circuit protectors installed? Yes No L. Is the unit adequately grounded? Yes No M. Are all electrical power connections tight? Yes No N. Have the compressor heaters operated continuously for 24 hours prior to start up? Yes No O. Does all electrical wiring conform to unit electrical diagram? Yes No P. Does all field wiring conform to electrical diagrams? Yes No Q . Are all service valves open? Yes No R. H a ve all the ship ping hold-down plates securing the fan frame been removed? Yes No S. Unit with ducted return, has the low side tubing for PC5 (dirty filter switch) been

Installed? Yes No T. Are all the cleanout plugs installed (condenser, condensate trap & optional

waterside economizer)? Yes No

IM708 39

START-UP

A. Does the unit start & perform per sequence of operation as stated in IM Bulletin? Yes No B. D oes the fan rotate in the right direction ? Yes No C. Condenser inlet water temperature Deg. F _____ D. Condenser outlet water temperature Deg. F. _____ E. Number of Compressors Operating Deg. F. _____ F. Return air temperature Deg. F . _____ G. Mixed air temperature Deg. F. _____ H. Supply air temperature Deg. F. _____ I. Compressor Readings:

Reading

Compressor #1Compressor #2Compressor #3Compressor #4Compressor #5Compressor

Suction Pressure, psig

Discharge Pressure, psig

Superheat Setting @ TXV Bulb, Deg. F

Compressor RLA (name plate)

Current, Line L1, amps

Current, Line L2, amps

Current, Line L3, amps

J. Electrical Heat Readings (When installed):

FLA amps (nameplate)

Reading

@ Contactor M11 @ Contactor M12 @ Contactor M15 @ Contactor M16

Current, Line Ll, amps

Current, Line L2, amps

Current, Line L3, amps

40 IM708

68KW Heat, 230v or 208v Only

K. Fan Motor Current Per Phase: amps amps amps

FLA: amps Variable Frequency Drive: % Speed / Hertz

L. Fan Speed: rpm at above frequency

M. Unit Voltage across each phase: volts volts volts N. Unit Current per phase: amps amps amps

CONTROL CHECK

A. Compressor Low and High Pressure Cut-outs:

Comp. No. 1 Comp. No. 2 C o mp. No. 3 Comp. No. 4 Low Press Cut-out, psig Low Press Cut-in, psig High Press Cut-out, psig

Comp. No. 5 Comp. No. 6 Low Press Cut-out, psig Low Press Cut-in, psig High Press Cut-out, psig

GENERAL

A. Are all control lines secure to prevent excessive vibration and wear? Yes No B. Are all gauge ports shut off, valve caps and packings tight after start-up? Yes No C. Are VAV boxes set to keep a minimum airflow of 40% of design? Yes No D. Do the Economizer, Water Regulating, and Hot Water valves rotate freely? Yes No

Performed By: Title:

Signature: Date of Start-up:

RETURN COMPLETED FORM TO:

McQuay International Warranty Department 13600 Industrial Park Boulevard Minneapolis, MN 55441

Comments:

IM708 41

13600 Industrial Park Boulevard, Minneapolis, MN 55441 USA (763) 553-5330

McQuay SWP 018, SWP 023, SWP 028, SWP 035, SWP 040 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual