Installation and Maintenance Manual IM 777-3 Skyline™ Air Handler Group: Applied Air Sizes 003–090 Part Number: IM 777 Date: October 2008 © 2008 McQuay International
Contents General Information ................................................. 3 Receiving and Handling...................................... 3 Unit Storage........................................................ 3 Nomenclature ..................................................... 3 Installation Guidelines ............................................. 4 Service Clearances............................................. 4 Rigging ...............................................................
General Information The system design and installation must follow accepted industry practice as described in the ASHRAE Handbook, the National Electric Code, and other applicable standards. Install this equipment in accordance with regulations of authorities having jurisdiction and all applicable codes.
Installation Guidelines Service Clearances Figure 2: Service Clearance for Electrical Power Devices Installation Guidelines In addition to providing adequate space around the unit for piping coils and drains, access to at least one side of the unit is always required to allow for regular service and routine maintenance, which includes filter replacement, drain pan inspection and cleaning, fan bearing lubrication, and belt adjustment.
Installation Guidelines Curb Mounting and Unit Leveling Do not place a Skyline unit over an open curb unless it is equipped with a curb-ready base. Installation instructions for mounting units on a roof curb are provided in IM 770. For a copy, contact your local McQuay representative or visit www.mcquay.com. Make provisions under the unit to divert any moisture from entering the building below. For units without roof curb mounting, place the equipment on a flat and level surface.
Installation Guidelines Figure 6: Remove Vestibule Lifting Bracket e Handle units with curb-ready bases and vestibules so the lifting bracket can be removed after the unit is placed on the curbing. – Remove the lifting bracket that projects inward over the curbing. Save the self tapping screws. – When the adjacent section is placed in position, use self tapping screw to secure the bases together.
Installation Guidelines Panels, Frame Channels, and Doors Panel Removal To remove a side or top panel, remove the flat head Torx 30 fasteners along the sides of the panel. Lift off the panel after removing all fasteners. Frame Channel Removal Frame channels that run the length of the unit along the top can be removed to allow access to both the side and top of the unit. To remove the frame channel, first remove the side panel(s).
Installation Guidelines Injected-Foam Insulated Panels Skyline air handlers now are furnished with double-wall, injected-foam insulated panels. Foam panels are stronger, more rigid, and lighter than panels with fiberglass insulation. The insulation R-value is improved to 13. However, foam insulation can burn when exposed to flame or other ignition sources and release toxic fumes. Take care in cutting and sealing all field-cut openings in these panels.
Installation Guidelines If the unit has a top mixing box or economizer damper or a top duct connection, field fabricate and install flashing to divert moisture from the connection. The flashing must lap over the standing seams of the top panels. The flashing also must lap over the side edges of the unit. See Figure 14. When units are ordered with exhaust hoods and intake hoods adjacent to each other, install a field-supplied barrier to prevent recirculation of exhaust air into the intake openings.
Installation Guidelines Figure 18: Seal Holes for Piping—Standard Base Rail Units CAUTION Maximum damper rotation is 70°. Maximum shaft torque is 205 inches/pound. Greater rotation or torque can cause equipment damage. ATTENTION La rotation maximale des volets est de 70°. Le couple (torque) maximum de l’arbre est de 205po/lb. Une plus grande rotation (ou torque) peut endommager l’équipement.
Installation Guidelines Steam Coils (see Figure 19 on page 12) Piping • Steam supply and steam return connections typically are male NPT iron pipe and are labeled on the end panel of coil section. Connections extend through the coil section end panel. • Multiple coil installation. Individually trap each coil or group of coils that is controlled individually trapped. Coils in series—use separate traps for each coil, or a bank of coils.
Installation Guidelines Figure 19: Piping Arrangements Float and thermostatic trap Check Valve Strainer Control valve modulating two position Gate Valve High Pressure (over 25 psi) Vacuum breaker 1/2" check valve Steam main Vacuum breaker 1/2" check valve 1/4" petcock for continuous air venting Steam main Return main 1" min. 12" min. 1/4" petcock for continuous air venting High pressure float or bucket trap 1" min. 12" min. High pressure bucket trap Full size of return conn.
Installation Guidelines Figure 20: Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet Water Heating Coils CAUTION Improper installation, use, or maintenance of water heating coils can cause equipment damage. Read and follow instructions carefully. Pressure (P) at the drain pan 2P ATTENTION Si l’installation, l’utilisation ou l’entretien des serpentins de chauffage à eau sont inadéquats, ceci endommagera l’équipement. Lire et suivre attentivement les instructions.
Installation Guidelines Internal Isolation Assembly Adjustment On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment. with a tie-down at each point of isolation. Figure 22: Removing Shipping Brackets Unit sizes 006 - 090 Before Operating the Unit: Remove the shipping brackets and tie-down bolts (see Figure 22) and discard. The shipping brackets located on the opposite drive side of the unit are difficult to access from the drive side of the unit.
Installation Guidelines Electrical Installation Figure 23: Electrical Conduit Location Wiring DANGER Capacitor hazardous voltage! Failure to disconnect power and discharge capacitors before servicing will result in serious injury or death. Disconnect all electric power (including remote disconnects) before servicing. Perform lockout/tagout procedures to ensure that power can not be energized.
Operation Guidelines Startup Checks Operation Guidelines When performing startup and service, always take thorough safety precautions. Only trained, experienced personnel should perform these functions. WARNING Rotating fan. Can cause severe injury or death. Before servicing fans, lockout and tag out power. AVERTISSEMENT Ventilateur en rotation. Peut causer des blessures sévères ou même la mort. Avant d’effectuer l’entretien des ventilateurs, bloquer et couper la tension.
Operation Guidelines the drives usually ship with the adjustment opened up for minimum fan speed. Adjust the drives for the proper airflow. See “Fan Drive Adjustments” on page 23. After the First 48 Hours of Operation: 2 Check tightness of all bearing, wheel, and sheave setscrews (or capscrews). See Table 6. 3 Recheck belt tension and adjust if necessary. Belts that are tensioned sufficiently to slip one to two seconds at startup perform satisfactorily, extending life and reducing vibration.
Operation Guidelines Figure 27: Wheel-to-Inlet Funnel Relationship—Inline Fans Table 6: Bearing Collar and Wheel Hub Set Screw Torque set screw Overlap Diameter (in) Minimum torque ft/lbs kg/m. 1/4 5.5 .76 1/16 10.5 1.45 3/8 19.0 2.63 7/16 29.0 4.01 1/2 42.0 5.81 5/8 92.0 12.72 Table 5: Wheel-to-Inlet Funnel Relationship—Inline Fans Wheel—funnel overlap 18 Size Overlap 150 .375 165 .438 182 .562 200 .625 222 .688 245 .750 270 .812 300 .875 330 1.000 365 1.
Operation Guidelines Operating Limits Do not exceed the operating limits in Table 7. A fan wheel operated beyond the rpm and temperature limits shown can suffer permanent distortion or fracture. The resulting unbalance can cause severe unit vibration. Table 7: Unit Sizes 003 to 035 Fan operating limits Forward curved—housed Diameter 9×4 9×7 9×9 10.62 12.62 15 18 20 22.25 24.
Operation Guidelines Figure 30: Torque for FC Variable Inlet Vanes (in–lb) 300 250 2000 50 .25 0 22 .0 20 FC C F 0 .0 0 18 .0 C F 15 62 C F 2. 1 FC . 24 150 100 90 80 70 60 1500 25 0. 4 AF 1000 900 800 700 600 500 400 350 300 250 200 Torque (in–lb) FC 200 50 8. 3 AF A 0 .0 3 F3 00 0. 3 AF 00 0 .5 24 2.25 F A F2 00 0. A 2 AF 7. 2 AF 150 3000 49 54.
Operation Guidelines Fan Vibration Levels Figure 32: Torque Requirements at 100% WOV for SWSI Plenum Fans with NESTED Inlet Vane Each unit as shipped is trim balanced to operate smoothly. To provide satisfactory operation after shipping and installation, use the accepted industry guidelines for field balancing fans. See Table 11. 60 0 5000 54 2 4000 49 0 3000 Table 11: Vibration Levels 44 5 Note: 1000 900 800 700 40 2 36 5 Torque (in-lb ) Torque (lb./in.
Service and Maintenance Periodic Service and Maintenance Service and Maintenance 1 Check all moving parts for wear every six months. 2 Check bearing collar, sheave, and wheel hub setscrews, sheave capscrews, and bearing hold-down bolts for tightness every six months. 3 Annually check and snug all electrical connections. Inspect for signs of water damage such as corrosion and repair if necessary. Check ground conductor and connection integrity. Service if needed.
Service and Maintenance Fan Drive Adjustments Table 14: Recommended Lubricants for Fan Shaft Ball Bearings Name Temperature Base Thickener NLGI grade Texaco, Premium RB Mobile, AW2 30° to 350°F (34° to 177°C) 40° to 437°F (40° to 175°C) 68° to 356°F (50° to 180°C) 60° to 450°F (51° to 232°C) Parafinic mineral oil Mineral oil Lithium 2 Lithium 2 Synthetic Lithium 2 Synthetic Lithium 2 40° to 300°F (40° to 149°C) Mineral oil Lithium 2 Mobile, SHC 100 Chevron, Altiplex Synthetic Exxon, r
Service and Maintenance VM and VP Variable Pitch Key Type Sheaves Mounting 1 Mount all sheaves on the motor or driving shaft with the setscrews A toward the motor. 7 Verify that all keys are in place and that all se screws are tight before starting drive. Check setscrews and belt tension after 24 hours service. Figure 33: VP Type Sheave Adjustment 2 Verify that both driving and driven sheaves are in alignment and that shafts are parallel.
Service and Maintenance LVP Variable Speed Sheaves 10 Before starting the drive, ensure that all keys are in place and all setscrews and all capscrews are tight. Check and retighten all screws and retension belts after approximately 24 hours of service. Mounting 1 Slide sheave on motor shaft so that the side of the sheave with setscrew A is next to the motor when setscrew A is in the hub or barrel of the sheave. Adjusting 1 Slack off belt tension if belts have been installed.
Service and Maintenance MVP Variable Speed Sheaves 4 Any pitch diameter can be obtained within the sheave Mounting: 1 Verify both driving and driven sheaves are in alignment and the shafts are parallel. The centerline of the driving sheave must be in line with the centerline of the driven sheave. See Figure 35. 2 Verify that all setscrews are torqued to the values shown in Table 16 before starting drive. Check setscrew torque and belt tension after 24 hours of service.
Service and Maintenance Figure 36: Sheave Adjustment F ix e d C e n te r - F la n g e A d ju s ta b le C e n te r - F la n g e ( 2 ) L o c k in g S e ts c re w s "A " F la th e a d S o c k e t S c r e w s (D o N o t R e m o v e ) S p lit T a p e r B u s h in g C a p s c re w s (D o N o t R e m o v e ) S ta tio n a r y E n d - F la n g e O u te r L o c k in g - R in g In n e r L o c k in g - R in g ( 3 ) H o le s fo r S p a n n e r W re n c h o r D r ift Fan Drive Belt Adjustment General Rules of Te
Service and Maintenance Table 17: Belt Deflection Force (per Browning® specifications) Sheave diameter (in) Cross section Smallest sheave diameter range 3.0 to 3.6 A, AX 3.8 to 4.8 5.0 to 7.0 3.4 to 4.2 B, BX 4.4 to 5.6 5.8 to 8.6 4.4-6.7 5V, 5VX 7.1-10.9 11.8-16.0 Deflection force (lbs) Cross section A, B, 5V Cross section AX, BX, 5VX rpm range Used belt New belt Used belt New belt 1000 to 2500 3.7 5.5 4.1 6.1 2501 to 4000 2.8 4.2 3.4 5.0 100 to 2500 4.5 6.8 5.0 7.
Service and Maintenance Winterizing Water Coils Table 18: Filter Pressure Drops Bag filters—DriPak 2000 Efficiency 45% 65% 85% 95% Rated velocity (fpm) 625 500 500 500 Initial pressure drop Initial pressure drop .20–.26 .21–30 .34–.48 1.0 1.0 1.0 .50–.70 1.0 Cartridge filters—Varicel II MH, 4.25" deep Efficiency 65% 85% 95% Efficiency Rated velocity (fpm) 500 500 500 Rated velocity (fpm) Initial pressure drop .43 .61 .70 Initial pressure drop Final pressure drop 1.5 1.5 1.
Service and Maintenance Removing the Fan Assembly 1 Remove the side panels and any intermediate supports (follow instructions for side panel removal). 2 Once the panels and any intermediate supports are Figure 40: Single Coil Top Installation/Removal Opposite connection end Connection end removed, disconnect the neoprene bulk head seal that is attached to the fan discharge. Coil 3 Remove the four discharge angles that hold the neoprene canvas in place around the discharge opening.
Service and Maintenance Removing Stacked Coils Note: Top and bottom stacked coils are held together with steel plate and screws on one side and drain trough and screws on the other side. Remove the plate and trough before removing the coils. The coils cannot be removed attached together. 1 Disconnect all piping and remove the brass plugs for the vents and drains located in the connections. 2 Remove all screws and remove the access panel.
Warranty Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your local McQuay Representative, go to www.mcquay.com. Warranty Warranty Return Material Procedure Defective material may not be returned without permission of authorized factory service personnel of McQuay International in Minneapolis, Minnesota, (763) 553-5330. A “Return Goods” tag must be included with the returned material.
Skyline Equipment Warranty Registration Form Skyline Equipment Warranty Registration Form To comply with the terms of McQuay Warranty, complete and return this form within 10 days to McQuay Warranty Department. Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery. Job Name:________________________________________ McQuay S.O. No.: _________________ McQuay G.O. No.
Skyline Equipment Warranty Registration Form H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control. . . . . . . . . . . . . . . . . . . . . . . . . . V. CHILLED WATER COIL A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Drain pan draining okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality Assurance Survey Report Quality Assurance Survey Report Quality Assurance Survey Report To whom it may concern: Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the product. Job Name: _____________________________________________________ McQuay G.O. no.
McQuay Training and Development Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority. For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training, or call 540-248-9646 and ask for the Training Department. Warranty All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product Warranty. Consult your local McQuay Representative for warranty details.
