Installation and Maintenance Manual IM 487-4 Group: Applied Systems Part Number: IM 487 Date: December 2004 RoofPak™ Applied Rooftop Systems Air Handler RAH 047C–077C 12000 to 50000 cfm RDS 800C–802C 4000 to 20000 cfm US © 2004 McQuay International
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gas Burner Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hazard Identification Information . . . . . . . . . . . . . . . . . . . . . . . 1 Typical Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . 2 Typical Unit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Introduction This manual provides general information about the “C” vintage McQuay RoofPak applied rooftop unit, models RDS and RAH. In addition to an overall description of the unit, it includes mechanical and electrical installation procedures, commissioning procedures, sequence of operation information, and maintenance instructions. For further information on the optional forced draft gas-fired furnace, refer to Bulletin No. IM 684 or IM 685.
Introduction Typical Component Locations Figure 2 shows a typical blow-through unit with the locations of the major components. Figure 2 shows a typical draw-through unit with the locations of the major components. These figures are for general information only. See the project’s certified submittals for actual specific dimensions and locations. Figure 2.
Introduction Figure 3.
Introduction Figure 4.
Introduction Typical Unit Sections The individual sections that make up a rooftop can vary from unit to unit. All available sections are shown in Figure 5 and Figure 6. Figure 5.
Introduction Figure 6. Typical unit sections (draw-through with SWSI supply fan) RETURN AIR OA/HOOD COIL FILTER DP ONLY TA/30 FLAT PLENUM 65/95 OPT EVAP COIL S & HW STAGG 30% OA STAGG OPT BLANK OUTSIDE AIRSTREAM MWU HEAT SA FAN BLANK STAGG ECONO BLANK BLANK STAGG ECONO/RA BLANK MIXING BOX STAGG ECON W/PROP. EXH. FANS, BOTTOM OR BACK RET. FANS ECON W/PROP. EXH. FANS, BOTTOM & SIDE RET. FANS Note: Views shown for 047C family.
Introduction Control Locations All controls are optional. If controls are ordered, Figure shows the locations of the various control components mounted throughout the units. See “Control Panel” on page 8 for the locations of control components mounted in control panels. Additional information is included in Table 2 on page 15 and the wiring diagram legend, which is included in “Wiring Diagrams” on page 57. Figure shows the blow-through heat and the blow-through coil sections. Figure 7.
Introduction Control Panel The unit control panels and their locations are shown in the following figures. These figures show a typical unit configuration. Specific unit configurations may differ slightly from these figures depending on the particular unit options. Figure 8.
Introduction Figure 9.
Introduction Figure 10.
Introduction Figure 11.
Introduction Figure 12. Typical gas heat panel, 1000 MBH Figure 14. VFD bypass panel, 40 HP, 460 volt) IT TD10 R20 AS R22 R23 R21 LS2 LS1 S3 Figure 15. Electric heat panel, sizes 800, 802C FSG FSG Time Figure 13.
Introduction Figure 16. Electric heat panel, 047C FB33 M33 FB32 M32 FB43 FB42 M43 M42 Figure 17.
Introduction Figure 18.
Introduction Controls, Settings, and Functions Table 2 below lists all of the unit control devices. Included in the table are the device symbol, a description of the device, its function, and any reset information, its location, any device setting, any setting ranges, differentials, and the device part number.
Introduction during shipment (winter road chemicals are of particular concern), clean it when received. Mechanical Installation All units should be carefully inspected for damage when received. Report all shipping damage to the carrier and file a claim. In most cases, equipment is shipped F.O.B. factory and claims for freight damage should be filed by the consignee. The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and all applicable codes.
Introduction Figure 20. Service clearances, unit with SWSI plenum supply fan 72" (1829 mm) A 72" (1829 mm) B C 60" (1524 mm) Roof walkway To roof access location D E F X 96" (2438 mm) Varies with unit arrangement. Refer to Certified Drawing and note below. Note: Sections with heating and/or cooling coils or DWDI supply fan must have noted service clearance on the control box side.
Introduction Overhead Clearance 1 Unit(s) surrounded by screens or solid walls must have no overhead obstructions over any part of the unit. b Overhead obstructions must be no less than 96" (2438 mm) above the top of the unit. 2 The following restrictions must be observed for overhead c There must be no overhead obstructions in the areas obstructions above the air handler section (see Figure 21): above the outside air and exhaust dampers that are farther than 24" (610 mm) from the side of the unit.
Introduction Roof Curb Assembly and Installation Locate the roof curb and unit on a portion of the roof that can support the weight of the unit. The unit must be supported to prevent bending or twisting of the machine. If building construction allows sound and vibration into the occupied space, locate the unit over a non-critical area. It is the responsibility of the system designer to make adequate provisions for noise and vibration in the occupied space. WARNING Mold can cause personal injury.
Introduction Figure 23. RAH roof curb assembly instructions Using remaining side supports in this area, align lengths on opposite sides of assembly and install a cross support "D" at each side. Detail A M L D 3.50" (90 mm) 8.75" (222 mm) G C M 81.00" (2057 mm) Inside A "Y" Inside H Equal Length Side Supports H L D 7.50" (191 mm) Supply Air B C "X" Inside 70.75" (1797 mm) D E 8.75" (222mm) F F 3.50" (90mm) 2.00" (51 mm) G Return Air See Detail "A" A E 87.
Introduction Figure 25. RDS roof curb assembly instructions 6.80" (173 mm) 1.50" (38 mm) 20.00" (508 mm) Inside 76.00" (1930 mm) Inside G C A H 7.50" (191 mm) Supply Air H 2.00" (5.1 mm) G D B C "X" Inside 38.80" (984 mm) D E F "XX" F "YY" Return Air See Detail "A" A E "Y" Inside B 85.00" (2159 mm) 62.80" (1594 mm) Table 3: RDS roof curb assembly instructions Unit size Fan 800–802C None (2) 15” FC 30" AF 40" AF McQuay IM 487-4 “X” “Y” in mm in 24.0 24.0 30.0 36.
Introduction Figure 26. Typical power wire entrance, curb view (RDS 800–802 shown; for exact values, refer to submittal) D A 20.0 6.8 6.0 1.5 RA OPNG SA OPNG 76.0 C B RPS only 97.0 B B A A D See Detail A 2 Typ 4 Typ 6.0 E Unit length minus 6.4 Detail A 7.5 8.0 12.1 5.1 0.9 Dia. K.O. 3.0 Dia. K.O. 3.4 2.1 3.1 4.3 2.0 4.6 4.8 9.7 Post and Rail Mounting When mounting by post and rail, run the structural support the full length of the unit.
Introduction Rigging and Handling Lifting brackets with 2" (51 mm) diameter holes are provided on the sides of the unit. Use spreader bars, 96" to 100" (2438 to 2540 mm) wide to prevent damage to the unit cabinet. Avoid twisting or uneven lifting of the unit. The cable length from the bracket to the hook should always be longer than the distance between the outer lifting points.
Introduction Lifting Points Figure 29. Unit type RAH lifting points z To determine the required lifting cable lengths and whether four-or six-point lifting is required, use Tables 4 and 5 and Figure 29. 4 Lifting Points Referring toFigure 29, note that dimension A is the distance between the outer lifting points. The four outer rigging cables must be equal to or longer than dimension A. Dimension B shows the minimum distance between the outer and the inner lifting points for six-point lifting.
Introduction Split Units Although units typically ship from the factory as complete units, they can be factory split at the supply fan bulkhead and connected later on the roof. This configuration is ordered if the shipping length or a weight limitation prevents ordering a packaged unit. A single nameplate is attached to the air handler section and power is supplied to both sections through the optional main control box as in a packaged unit.
Introduction Phase II. Reassemble cabinet (Figure 31) 1 Reinstall top cap removed in Phase I, Step 1. 2 Caulk (watertight) ends of splice cap. 3 Caulk (watertight) vertical seam. 4 Install #10 screws (provided). 5 Install screws (.25–20 ×.75) removed in Phase I, Step 2. 6 Install splice cover (provided). Figure 31. Reassemble cabinet Reinstall top cap saved in step 1 Caulk ends of splice cap Splice cover, provided #10 screws, provided Caulk vertical seam See detail Install screws (.25 to 20 × .
Introduction Phase III. Reconnect power and control wiring Field Refrigerant Piping and Charging of DX Coils Once the sections are physically reconnected, the ends of the power harness are fed back through the unit base into the junction box, per the unit’s electrical schematics. Units that ship from the factory with DX coils installed do not include refrigerant piping or refrigerant controls. The coil assembly is ready for field connections at the distributors and at the suction headers.
Introduction Piping Recommendations 1 Use type K or L clean copper tubing. Thoroughly clean or braze all joints with high temperature solder. 2 Base piping sizes on temperature/pressure limitations as recommended in the following paragraphs. Under no circumstances should pipe size be based strictly upon coil or condensing unit piping connection size. 3 Do not exceed suction line piping pressure drop equivalent to 2°F (1°C), 3 psi (20.7 kPa) per 100 feet (30.5 m) of equivalent pipe length.
Introduction Table 7: Pressure-vacuum equivalents Absolute pressure above zero Microns 0 50 100 150 200 300 500 1,000 2000 4,000 6000 8,000 10,000 15,000 20,000 30,000 50,000 100,000 200,000 500,000 760,000 PSIA 0 0.001 0.002 0.003 0.004 0.006 0.009 0.019 0.039 0.078 0.117 0.156 0.193 0.290 0.387 0.580 0.967 1.930 3.870 9.670 14.697 Vacuum below 1 atmosphere Mercury (mm) 760.00 759.95 759.90 759.85 759.80 759.70 759.50 759.00 758.00 756.00 754.00 752.00 750.00 745.00 740.00 730.00 710.00 660.00 560.
Introduction Unit Piping Refrigerant Charge Factory-installed DX coils are designed to use R-22. The total charge per circuit is the sum of the following three values: • Condenser section charge. Refer to manufacturer’s data. • Evaporator coil charge. • Charge for length of interconnecting piping, installed by field. Note: Factory-installed DX coils are intended for one refrigerant circuit on unit size 800 and two refrigerant circuits containing identical weights of refrigerant on all other sizes.
Introduction • Because drain pans in any air conditioning unit have some moisture in them, algae, etc. will grow. Periodically clean to prevent this buildup from plugging the drain and causing the drain pan to overflow. Clean drain pans to prevent the spread of disease. Cleaning should be performed by qualified personnel. WARNING Drain pans must be cleaned periodically. Material in uncleaned drain pans can cause disease. Cleaning should be performed by qualified personnel. Figure 33.
Introduction Hot Water Piping Note: Factory-installed water valves and piping are bronze, Hot water coils are provided without valves for field piping or piped with three-way valves and actuator motors. With the factory piping and valve package, the two coils are piped in parallel and controlled through a single three-way valve. Field piping connections are of the same NPT size as the valve-male threads at the supply connection, female threads at the return connection.
Introduction Figure 36. Two-way valve package Steam Trap Recommendations 1 Size traps in accordance with manufacturers’ recommendations. Be certain that the required pressure differential will always be available. Do not undersize. 2 Float and thermostatic or bucket traps are recommended for low pressure steam. Use bucket traps on systems with onoff control only. 3 Locate traps at least 12" (305 mm) below the coil return connection.
Introduction Steam Coil Freeze Conditions Chilled Water Piping If the air entering the steam coil is below 35°F (2°C), note the following recommendations: Chilled water coils are provided without valves for field piping, or piped with three-way valves with motor actuators. Table 11 provides information on units with factory installed piping and valve packages. The table also provides field sweat connection information for units not furnished with factory installed piping and valve packages.
Introduction Table 11: Piping connection sizes/valve size options for chilled water piping Cabinet size Application code Coil size Available rows Face area sq. Hx 83" (available with 8, ft. (sq. m) (2108 mm) 10, 12 fins/in) long 33 + 33 Blow-thru or (2 coils) (838 draw-thru small + coil section 838 mm) 38.0 (3.53 m²) 39 + 39 Blow-thru or (2 coils) (991 draw-thru large + coil section 991 mm) 45.0 (4.
Introduction Table Available Circuiting Legend Column 1: These units are available with a factory installed package consisting of a three-way water valve and connecting piping. A = This combination is not available with a factory-installed piping and valve package. B = 300, 2.50, or 200 inch three-way valves can be specified C = 300, 2.50, 2.00, or 150 inch three-way valves can be specified D = 250, 200, or 150 inch three-way valves can be specified E = 250, 200, 150, or 1.
Introduction Vestibule Assembly Instructions Step 2 An accessory vestibule is available to provide additional piping space for coils installed in a four-foot section. A vestibule is required to maintain door access on a combination heating and cooling section. Assemble the vestibule to the unit part by part as shown in Figure 41. Remove gasketing around door flange and save for use on vestibule. See Step 4. Remove door and save for Step 4. Figure 42.
Introduction Step 3 Step 4 1 Assemble side panels A and B to uprights using #10 drill screws supplied. Make certain side panels are flush against uprights before securing into place. 2 Fasten bottom panel D to base channel using #10 drill screws and to side panels A and B using #10 screws supplied. 3 Set top panel C in place and fasten to side panels A and B using #10 screws and to top panel using #10 screws supplied.
Introduction Damper Assemblies The optional damper assemblies described in this section normally are ordered with factory-installed actuators and linkages. The following sections describe operation and linkage adjustment of the factory option. Economizer Dampers Outside air intake is provided on both sides of the unit, and the return air path is at the center of the damper set. As the single actuator modulates the outside air dampers open, the return air dampers close.
Introduction Intake Hood Damper (0% to 100% outside air, RAH 47–77 only) Figure 47. Intake hood damper adjustment, 0% to 100% outside air Units requiring 100% outside air are provided with a rain hood and dampers that can be controlled by a single actuator. The actuator provides two-position control for opening the dampers fully during unit operation and closing the dampers during the off cycle. No unit mounted exhaust dampers are provided.
Introduction Mixing Box (RAH 47–77 only) This section uses an outside air damper and a return air damper. Using these dampers allows outside air to blend with return air. Synchronized operation of the dampers is accomplished by interconnecting rods. As one damper section opens, the other section is closed. A total of 100% cfm is always drawn from this section. Damper positioning can be manually or automatically adjusted. With a field-installed controller, automatic operation can be obtained.
Introduction Face and Bypass Dampers Face and bypass dampers are available in a flat arrangement for use with heating coils and standard face area cooling coils, as well as a staggered arrangement for large face area cooling coils. The damper sets are linked through a jack shaft for connection to a single actuator (factory or field installed). Figure 49. Face and bypass dampers, RDS 800–802 only Airflow Face Dampers Open Face and Bypass Damper .75" (19mm) 90 Stroke 3.
Introduction Figure 51. Face and bypass dampers, flat arrangement—RAH 47–77 only Optional Contractor Coil Face and Bypass Damper Extended Shaft Face and Bypass Dampers Cabinet Weather Protection This unit ships from the factory with fully gasketed access doors and cabinet caulking to provide weather resistant operation. After the unit is set in place, inspect all door gaskets for shipping damage and replace if necessary. Protect the unit from overhead runoff from overhangs or other such structures.
Introduction Installing Ductwork On bottom-supply/bottom-return units if a McQuay roof curb is not used, installing contractor should make an airtight connection by attaching field fabricated duct collars to the bottom surface of either the roof curb’s duct flange or the unit’s duct opening. Do not support the total weight of the duct work from the unit or these duct flanges. See Figure 52. Units with optional back return, side discharge, or end discharge all have duct collars provided.
Introduction Installing Duct Static Pressure Sensor Taps Figure 53. Static pressure tubing entrance location For all VAV units, duct static pressure taps must be field installed and connected to the pressure sensors in the unit. Sensor SPS1 is standard; additional sensor SPS2 is optional. These sensors are located in the main control panel (see “Control Panel” on page 8). Carefully locate and install the duct static pressure sensing tap.
Introduction Installing Building Static Pressure Sensor Taps If a unit has direct building static pressure control capability, you must field install and connect static pressure taps to pressure sensor SPS2 in the unit. This sensor is located at the bottom of the main control panel next to terminal block TB2 (see “Control Panel Locations” in the “Unit Description” section of this manual). Carefully locate and install the two static pressure sensing taps.
Electrical Installation Electrical Installation Field Power Wiring All of the unit side panels are hinged. Do not mount disconnect switches and/or motor starters on panels that provide access to internal components. Wiring conduits can penetrate the cabinet bottom, base frame, or through the hinge and latch cap without interfering with the access panels. Note: All holes cut into the unit must be sealed to prevent water leakage.
Electrical Installation • The preferred entrance for power cables is through the bottom knockouts provided on the unit. If side entrance is the only option, a drilling location is provided. Figure 57. Optional side power wiring entrance 3 " (7 6 m m ) M a x D ia . CAUTION M a in C o n tro l P a n e l Wires are located in base rail. Move wires before drilling hole through base rail. 2 .7 5 " (7 0 m m ) The drilling dimensions must be followed exactly to prevent damage to the control panel.
Electrical Installation All Units The minimum circuit ampacity (wire sizing amps) is shown on the unit nameplate. Refer to Table 13 on page 49 for the recommended number of power wires. Copper wire is required for all conductors. Size wires in accordance with the ampacity tables in Article 310 of the National Electrical Code. If long wires are required, it may be necessary to increase the wire size to prevent excessive voltage drop. Wires should be sized for a maximum of 3% voltage drop.
Electrical Installation Field Control Wiring Units are available with several control arrangements which may require low voltage field wiring. Detailed descriptions of various field control wiring options and requirements are included in the “Field Wiring” section of Bulletin No. IM 696, “MicroTech II Applied Rooftop Unit Controller.” Refer to the unit wiring diagrams for additional installation information. Wiring must comply with applicable codes and ordinances.
Preparing Unit for Operation Preparing Unit for Operation Figure 63. Fan spring mount adjustment WARNING Moving machinery hazard. Can cause severe injury or death. Before servicing equipment, disconnect power and lock off. More than one disconnect may be required to de-energize unit. Figure 61.
Preparing Unit for Operation Adjusting Scroll Dampers Figure 65. Thrust restraint adjustment Two sets of scroll dampers are provided in the housing of the twin 15" x 6" supply fan to allow control of air volume to each fan wheel. At the factory, these dampers are fully closed, unrestricting airflow. If fan paralleling occurs, correct it by loosening the adjustment screw on top of the fan housing (see Figure 64) and slightly lowering the rod until air distribution between the fans is even.
Preparing Unit for Operation Adjusting Seismic Restraints Figure 66. Cross section of seismic restraint Spring-mounted supply air and return air fans can be ordered with factory-installed seismic restraints. The system consists of four snubbers, one located next to each spring isolator. These snubbers allow free movement of the fan assemblies during normal operation because normal operation does not cause fan movements that exceed .25" (6 mm).
Sequences of Operation Sequences of Operation The following sequences of operation are for a typical “C” vintage applied rooftop unit equipped with MicroTech II, an economizer, 3 to 1 turn down burner, variable frequency drives (VFD), a return air fan and an external time clock. These sequences describe the ladder wiring diagram logic in detail; refer to “Wiring Diagrams” on page 57 as you read them. Note that your unit’s sequences of operation may vary from those described here.
Sequences of Operation Fan Operation Economizer Operation When the main control board (MCB) commands the supply and return fans to start, the unit enters the Startup operating state. As a result, a 3-minute timer is set, output MCB-BO3 (line 307) energizes, and relay R26 energizes (line 306). When the outdoor air is suitable for free cooling, the switch in enthalpy sensor OAE is in position “3” (line 252) energizing binary input MCB-BI11. When MCB-BI11 energizes, the economizer is enabled.
Sequences of Operation Heating Gas Furnace, Modulating Burner (3 to 1 turn down) Refer to “Standard Mod, furnace control (1000 MBH)” on page 78 as you read this sequence of operation. Note that the gas furnace wiring diagrams supplied with the units include a detailed sequence of operation. Refer to the wiring diagram supplied with the unit for exact wiring and sequence of operation information. When system switch S1 is closed, 115 VAC power is supplied to the furnace control circuit.
Wiring Diagrams Wiring Diagrams Legend ID ACT3, 4 ACT5 ACT6 ACT7 ACT8 ACT10, 11 ACT12 AFD10 AFD11 AFD20 AFD60 AS BM C10 C20 CB10 CB11 CB20 CB60 CCB1, 2 CPC CPR DAT DFLH DFRH DHL DS1 DS2 DS3 EAT EFT EHB1 ID Description Actuator motor, economizer Actuator motor, discharge isolation damper Actuator motor, return air isolation damper Actuator motor, heat face/ bypass Actuator motor, cool face/ Bypass Actuator motor, exhaust dampers Actuator motor, enthalpy wheel bypass damper Adjustable frequency drive, supp
Wiring Diagrams ID M10 M20 M29 M30 M31–39 M40 M41–50 M60 MCB MJ MMP1–8 MMP10 MMP11– 18 MMP20 MMP21– 28 MMP30 MMP40 MMP51, 52, 53 MMP60 MP1–6 OAE OAT PB1, 2 PB3 PB9, 10 PB11, 12 PB19, 20 PC5 PC6 PC7 PC8 PM1 PVM1, 2 R20 R21, 22 R23 R24 R25 58 Description Contactor, supply fan Contactor, return fan Contactor, burner motor Contactor, reversing, invertor bypass, supply fan Contactor, electric heat (top bank) Contactor, reversing, Invertor Bypass, Return Fan Contactor, electric heat (bot.
Wiring Diagrams ID Description T9 TB1 TB2 TB3 TB4 TB7 Transformer, refrig.
60 134 133 132 131 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 CUSTOMER SUPPLIED POWER ELECTRICAL CIRCUIT #1 G L3 L2 L1 GLG1 T3B T3A T2B T2A T1B T1A DS1 (Schematic continues on next page.) Wiring Diagrams Figure 67.
McQuay IM 487-4 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 135 108 T3-1 T2-1 T1-1 168A 151 150 149 139 138 137 /2.
243 242 241 240 239 238 237 236 235 234 233 232 231 230 229 228 227 226 225 224 223 222 221 220 219 218 217 216 215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 T2_115VAC 168A 200 TB2 TB2 1 1 +PP PL11 228A 2 67 +PP 238A PL11 6 56 S1 +PP PL21 17 115 16 TB2 7 68 PL11 +PP 4/R-COM (ECON/OADM) +NB ACT3 H 6 H316-7 1-CCW BLK H267-1 H237-3 WHT H267-2 H237-5 H235-6 H (20VA PILOT DUTY MINIMUM CONTACT RATING) (CLOSE) H315-6
McQuay IM 487-4 270 269 268 267 266 265 264 263 262 261 260 259 258 257 256 255 254 253 252 251 250 249 248 247 246 245 244 6 219 R63 7 26OA 13 426 M10 14 (DUCT HI-LIMIT) 256A 260B 256B (S.A. FAN AUX CONTACT) 108 106 TB2 TB2 104 105 NOTE: THESE CONTACT ARE FOR USE IN A 24 VOLT A.C. CLASS #2 CIRCUIT. TB2 TB2 (Schematic continues on previous page.) Wiring Diagrams Figure 70.
64 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 CUSTOMER SUPPLIED POWER ELECTRICAL CIRCUIT #1 109 L3-3 L2-3 L1-3 PB11 T1A GLG1 G 139 138 137 T3B T3A T2B T2A T1B L3 L2 L1 DS2 L3 L2 L1 CB10 T3 T2 T1 H139 H138 H137 GND10 135A 134A 133A C1 B1 A1 +BB LR10 U1 139A 138A W1 V1 L3B GND 440 +NB AFD10 T3A T3B L3A H140 C2 B2 A2 137
McQuay IM 487-4 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149 148 147 146 145 144 143 168A /2.00 /8.00 T1_115VAC 109 L3-1 L2-1 L1-1 PB11 109 L3-6 L2-6 L1-6 PB11 164 162 151 150 149 164 163 162 L3 L2 L1 CB20 T3 3 2 1 1 2 3 4 H151 H150 TB1A 203 PVM1 T2 T1 H149 1 1 1 F1C F1B F1A 2 2 2 115T1/2.
66 141 140 139 138 137 136 135 134 133 113 112 111 110 109 108 107 106 109 L3-3 L2-3 L1-3 PB11 CUSTOMER SUPPLIED POWER ELECTRICAL CIRCUIT #1 139 138 137 426 T3A T3B L3A L3B T2A T2B L2B T1B L1B L2A T1A L1A 139A 138A T1 426 T3 T2 (Schematic continues on next page.) L3 L2 L1 GLG1 G M10 111A T3 L3 137A 110A T2 L2 MMP10 109A T1 L1 DS1 HSAF-3 HSAF-2 HSAF-1 L3B L3A L2B L2A L1B L1A PB11 T3 T2 T1 MTR SUPPLY-FAN Wiring Diagrams Figure 73.
McQuay IM 487-4 170 169 168 167 166 165 164 163 162 161 152 151 150 149 148 147 146 145 144 168A /2.00 /8.00 T1_115VAC 109 L3-1 L2-1 L1-1 PB11 109 L3-6 L2-6 L1-6 PB11 151 150 149 162 TB1A 1 2 3 4 T3B L3B 164 T3A L3A T2A T2B L2B T1B L1B L2A T1A 426 MMP20 L1A 1 1 1 F1C F1B F1A 2 2 2 L3 L2 L1 T3 T2 T1 168B 164A 162A 431 M20 H1 X3 H2 X2 H3 X1 H4 T1 TB1A GRD 5 6 7 8 (Schematic continues on the previous page.
233 232 231 230 229 228 227 226 225 224 223 222 221 220 219 218 217 216 215 214 213 212 211 210 209 208 207 206 205 204 203 202 201 T1_115VAC 168A 200 1 3 TB2 101 TB_101 4 +PP PL15 610 R24 5 203A 200A 156 PVM1 4 5 H231-1 1/R 128 129 GRD +NB FS1 +NB PC7 3/Y 2 H231-3 H228-1 101 HEAT_ENABLE 209A 210A 211A 2 S7 3 1 1 +PP PL15 OFF AUTO ON SHOWN IN NIGHT OR UNOCCUPIED MODE IS LOCATED ON DEADFRONT MANUAL_ENABLE AIR FLOW 1 TB2 A (DB9-MALE) CO
McQuay IM 487-4 270 269 268 267 266 265 264 263 262 261 260 259 258 257 256 255 254 253 252 251 250 249 248 247 246 245 244 243 242 241 240 239 238 237 236 235 234 203B /3.00 /4.00 /8.
237 236 235 234 233 232 231 230 229 228 227 226 225 224 223 222 221 220 219 218 217 216 215 214 213 212 211 210 209 208 207 206 205 204 203 202 168A 203B 201 /1.
McQuay IM 487-4 269 268 267 266 265 264 263 262 261 260 259 258 257 256 255 254 253 252 251 250 249 248 247 246 245 244 243 242 241 240 239 238 237 236 235 234 233 232 231 230 203B /3.00 /8.
334 333 332 331 330 329 328 327 326 325 324 323 322 321 320 319 318 317 316 315 314 313 312 311 310 309 308 307 306 305 304 303 302 SOURCE 1-8 WIRED INTERNAL TO MOTHERBOARD MCB BO4 TB1C 19 jprs 18 303A 115V T3 TB1C 20 21 H313-1 BO5 24V SRC jprs L1 +NB ACT3 307A 305A 239 H313-2 TB2 TB2 116 115 +PP PL11 (FAN_OPERATION) (EXT_ALARM_SIGNAL) 2 R26 10 TB2 117 207 (CLOSE) 5 MCB H315-6 5NO 318A 2-CW 7 PL11 H316-7 +PP X-COM (ECON/ACT) 24V SRC jprs
McQuay IM 487-4 369 368 367 366 365 364 363 362 361 360 359 358 357 356 355 354 353 352 351 350 349 348 347 346 7 H344-7 H343-6 X-COM 33 RECT AC RECTIFIER M HEAT + DC AC 36 TB1F L1 2-CW 24V SRC jprs TB1F 10NO B10 207 (OPEN) 10 MCB 9 345 344 +PP PL18 6 +PP PL18 339A 339C TB1F TB1F L2 3-CCW 34 35 362A +NB VM1 243 +PP PL18 H343-9 343 342 341 340 339 338 368A 367A H344-8 H343-5 jprs L1 X1 8 R26 306 9 R26 306 5 115V 12V 24V SRC
433 432 431 430 429 428 427 426 425 424 423 422 421 420 419 418 417 416 415 414 413 412 411 410 409 408 407 406 405 404 403 402 401 +PP PL7 H426-3 +BB MMP30 45 +PP PL8 H426-1 TB2 42 +PP PL8 MCB BO1 3 11(31) 133 12(32) H426-6 207 SRC MCB 6 +PP PL7 9-16 426A SOURCE 9-16 WIRED INTERNAL TO MOTHERBOARD 1 11(31) 145 H426-4 12(32) +BB MMP40 401A +PP PL18 5 R25 BO13 BO14 15NO 15 BO16 11NO BO11 SIG_1/6.
450 14 +PP PL7 445A 6 8 401 R67 7 5 12 239 R61 16 INCR H2UP 445B 10 3 9 14 H2V 405 R46_47 DECR H2DN +PP PL7 449 425 14 H443-14 11 137 261 13 430 +BB M40I 14 H443-15 H443C 15 +PP PL8 13 445C 11 6 8 404 R68 7 5 12 INCR 241 R66 16 H2UP 445D 10 RAF ABB401 +NB AFD20 3 9 409 R48_49 H2V +PP PL8 448 13 +BB M30I H443A 13 SAF ABB401 +NB AFD10 14 149 264 DECR H2DN +PP PL8 447 446 445 444 443 442 441 440 439 438 437 436 H443-7 7 443A H4
636 635 634 633 632 631 630 629 628 627 626 625 624 623 622 621 620 619 618 617 616 615 614 613 612 611 610 609 608 607 606 605 604 603 602 601 201A H603-1 1 1 3 628 R21 2 LS2 TB11 NO 621A (FLAME ROD) FD TB11 2 COM HL22 SIG_1/4.
McQuay IM 487-4 668 667 666 665 664 663 662 661 660 659 658 657 656 655 654 653 652 651 650 649 648 647 646 645 644 643 642 641 V V AIR SWITCH TEST CONN. MODULATING ACTUATOR BURNER BLOWER TEST COCK GV5B GV4A GV5A VALVE AND MANUAL VALVE. (TYPICAL) GV4B VALVE AND PRESS. REG. COMBINATION GAS CONTROLS GV1B --MAIN GV1A --FIRST IF THE UNIT OVERHEATS, THE HIGH LIMIT CONTROL (FLC) WILL CYCLE THE BURNER, LIMITING FURNACE TEMPERATURE TO THE LIMIT CONTROL SET POINT.
636 635 634 633 632 631 630 629 628 627 626 625 624 623 622 621 620 619 618 617 616 615 614 613 612 611 610 609 608 607 606 605 604 603 602 601 201A H603-1 1 HL22 2 RED_G630-B 618 (FLAME ROD) FD TB11 2 SIG_1/4.
McQuay IM 487-4 670 669 668 667 666 665 664 663 662 661 660 659 658 657 656 655 654 653 652 651 650 649 648 647 646 645 644 643 642 TEST CONN. AIR DAMPER MOD. GAS VALVE AIR SWITCH TEST CONN. TEST COCK BURNER BLOWER PILOT VALVE GV1 GV3 GV2 MAIN GAS VALVES PRESS. REG. MAIN PRESS. REG. PILOT COCK IF THE UNIT OVERHEATS, THE HIGH LIMIT CONTROL (FLC) WILL CYCLE THE BURNER, LIMITING FURNACE TEMPERATURE TO THE LIMIT CONTROL SET POINT.
80 533 532 531 530 529 528 527 526 525 524 523 522 521 520 519 518 517 516 515 514 513 512 511 510 509 508 507 506 505 504 503 502 501 500 HTR4A HTR3A HTR2A HTR1A L3 L1 L3 L1 L3 L1 L3 L1 L2 L2 L2 L2 518A 514A 510A 506A 519A 515A 511A 507A 520A 516A 512A 508A 4 3 4 3 4 3 2 1 4 3 (MANUAL) HL4 2 1 (MANUAL) HL3 2 1 (MANUAL) HL2 2 1 (MANUAL) HL1 519B 518B 515B 514B 511B 510B 507B 506B M31 T3 T2 T1 M34 T3 T2 T1 M33
570 569 568 567 566 565 564 563 562 561 560 559 558 557 556 555 554 553 552 551 550 549 548 547 546 545 544 543 542 541 540 539 538 537 536 2 1 5A 6A 5 3 STAGE 1 24C 1 +PP PL12 3 1 TB11 TB11 11 M34 4A M33 3A M32 2A M31 1A 207 MCB 120 KW 11NO 544B BO11 8 13 9 6 BI12 J10 7B 8B M41 1B M42 2B M43 3B M44 4B HEATER BANK "B" STAGE 6 STAGE 5 STAGE 4 STAGE 3 STAGE 2 120 KW 12 11 10 7 4 2 4 556A 554A 552A 550A 548A +PP PL12 +PP
Wiring Diagrams Figure 89. Fan control, power package only /1.
Wiring Diagrams Figure 90. CV fan control (SAF and RAF) /3.11 115VAC_GF/1 T3_24V TB2 TB2 45 jprs 24V SRC MCB BO2 9-16 MMP10 R68 404A 2 MMP20 R67 426A 10 M10 426B 11(31) 12(32) 10 2 2 2NO 207 RETURN FAN 11(31) /1.68 T1_N 401A jprs 24V SRC /3.11 T3_COM R67 1 1NO 207 SUPPLY FAN 42 SOURCE 9-16 WIRED INTERNAL TO MOTHERBOARD MCB 207 SRC MCB BO1 426C 12(32) 3 1 A1 A2 401 R68 M20 431A 3 1 A1 A2 404 Figure 91.
Unit Options Unit Options Enthalpy Control Figure 92. Enthalpy control settings 8 5 9 0 (2 9 .5 ) (3 2 ) 0 .8 0 0 .9 0 4 2 3 5 (1 .5 ) 4 0 (4 .5 ) 4 5 (7 ) 0 .6 0 0 .5 0 0 .3 0 0 .4 0 6 5 (1 8 .5 ) A B 0 . 2 0 C D 0 0 .1 Ground Fault Protection The ground fault protection is designed to protect motors from destructive arcing ground faults. The system consists of a ground fault relay and a ground fault current sensor.
Unit Options Smoke and Fire Protection McQuay optionally offers factory installed outdoor air, return air, and exhaust air dampers as well as smoke detectors in the supply and return air openings, complete with wiring and control. These components often are used in the building’s smoke, fume, and fire protection systems.
Unit Options Duct High Pressure Limit The duct high pressure limit control (DHL) is provided on all VAV units. The DHL protects the duct work, the terminal boxes, and the unit from over pressurization, which could be caused by, for example, tripped fire dampers or control failure. The DHL control is factory set to open when the discharge plenum pressure rises to 3.5" w.c. (872 Pa). This setting should be correct for most applications; however, it is adjustable.
Unit Options Variable Frequency Drive Operation Refer to the vendor instructions supplied with the unit. Convenience Receptacle/Section Lights A Ground Fault Circuit Interrupter (GFCI) convenience receptacle is provided in the main control box on all units. To use this receptacle, connect a separate field-supplied 115V power wiring circuit to the 115V field terminal block TB7, located in the main control box. screws.
Unit Options Figure 96. Tape fulcrum alignment plate to vane Figure 97. Place leveling weight on fulcrum V a n e D u c t T a p e T h is E d g e F lu s h w ith B o tto m o f V a n e T h F lu B o V a e s e E d g e s s h w ith tto m o f n e A lig n m e n t P la te F u lc r u m D u c t T a p e 9 Locate and install the fulcrum used in the leveling procedure as follows (see Figure 96): a Wipe the bottom of the louver door where the fulcrum will be located so that the duct tape will stick to it.
Unit Options Making Level Adjustments 7 When finished making the adjustments, tighten the .25-20 The DesignFlow unit is mounted so that it pivots at the top when three lock nuts are loosened, two at the top and one at the bottom of the assembly (see Figure 98). Leveling the unit involves precisely pivoting the assembly with a known force applied to the vane until the vane opens to a specific position.
Unit Options Propeller Exhaust Fan Option Figure 102. Fan rotation Economizer units may include propeller exhaust or centrifugal return fan options. This section covers maintenance and operating instructions for the propeller exhaust option. Centrifugal return fan construction, maintenance and operation is similar to that for supply fans and covered in other sections of this manual. A ir flo w A ir flo w R o ta tio n R o ta tio n Figure 101.
Unit Options Figure 103. Belt adjustment Figure 104. Drive pulley alignment M u s t b e p a r a lle l B e lt S p a n 6 4 D e fle c tio n = B e lt S p a n B e a r in g C e n te r lin e s m u s t c o in c id e M o to r M u s t b e p a r a lle l A d ju s ta b le S h e a v e Table 15: Propeller exhaust fan troubleshooting Problem Reduced Airflow Excessive Noise Cause Corrective Action System resistance is too high. Unit running backwards. Fan speed too low. Excessive dirt on propeller.
Unit Options Bearings Exhaust Fan Troubleshooting Bearings are the most critical moving part of the fan and should be inspected at periodic intervals. Locking collars and set screws, in addition to fasteners attaching the bearings to the bearing plate, must be checked for tightness. In a clean environment and temperatures above 32°F/below 200° F, fan shaft bearings with grease fittings should be lubricated semiannually using a high quality lithium based grease.
Unit Options Ultraviolet Light Operation Refer to the wiring schematic below. 115 VAC power for the UV lights is provided by control circuit transformer T1. The lights operate whenever the unit is powered, system switch S1 is closed, and all doors with door power disconnect switches are closed. To turn the lights off, disconnect power to the entire unit, or open system switch S1. The normally open disconnect switches are wired in series in a circuit that supplies 24VAC to the coil of relay R45.
Check, Test, and Start Procedures Check, Test, and Start Procedures All units are completely run tested at the factory to promote proper operation in the field. Nevertheless, the following check, test, and start procedures must be performed to properly start the unit. To obtain full warranty coverage, complete and sign the check, test, and start form supplied with the unit and return it to McQuay International. WARNING Electric shock and moving machinery hazard.
Check, Test, and Start Procedures Note: If desired, you can significantly reduce all MicroTech II internal control timers by the changing the entry under keypad menu Setup/Service\Unit Configuration\Timer Settings\Service= from “0 min” to “X min” where X is the number of minutes you want the unit to operate with fast timers. Power Up 1 Close the unit disconnect switch.
Check, Test, and Start Procedures Heating System Start-up Air Balancing General 1 At the keypad, set the heating setpoints high enough so that the controller will call for heating. The value in Temperature \ Zone Heating \ Occ Htg Spt= will need to be adjusted above the temperature shown in Temperature \ Zone Heating \ Control Temp=.
Check, Test, and Start Procedures Sheave Alignment Drive Belt Adjustment Mounting: 1 Verify both driving and driven sheaves are in alignment and the shafts are parallel. The center line of the driving sheave must be in line with the ce1nter line of the driven sheave. See Figure 108. General Rules of Tensioning 1 The ideal tension is the lowest tension at which the belt will not slip under peak load conditions.
Check, Test, and Start Procedures Mounting and Adjusting Motor Sheaves Figure 110. VM and VP variable pitch sheaves A 5 Put on belts and adjust the belt tension. Do not force belts over grooves. Loosen the belts by adjusting the motor base closer to the fan shaft. 6 Be sure that all keys are in place and that all setscrews are D tight before starting the drive. Check the setscrews and belt tension after 24 hours of service.
Check, Test, and Start Procedures Reinsert locking screws A, but do not tighten them until after adjustment is made. 9 Before starting the drive, make sure that all keys are in place and all setscrews and all capscrews are tight. Check and retighten all screws and re-tension the belts after approximately 24 hours of operation. 3 Adjust the sheave to the desired pitch diameter by turning the outer locking ring with a spanner wrench. Any pitch diameter can be obtained within the sheave range.
Check, Test, and Start Procedures Figure 113.
Final Control Settings Final Control Settings When all start-up procedures are completed, set the controls and program the MicroTech II controller for normal operation. Use the following list as a guide; some items may not apply to your unit. For more detail, see IM696 and OM137 or OM138. 1 Turn system switch S1 to ON and S7 to AUTO. 2 Turn gas furnace switch S3 to AUTO or turn electric heat switch HS1 to ON. 3 Set the electromechanical (Honeywell H205) enthalpy control (OAE) as required (A, B, C, or D).
102 CANCEL BACK Sub Menus 7 8 Previous Alarms Occupancy= _____ Occ Mode= Auto OccSrc= _____ Tnt Ovrd= 0 min Emerg Override= Norm UnitStatus= _____ Clg Capacity= xxx% Htg Capacity= xxx% Clg Status= _____ Htg Status= _____ Clg Capacity= xxx% Eff Clg Spt= xxx.x°F DAT Clg Spt= 55.0°F [1=1 or 3] Clg Db= 2.0°F Htg Capacity= xxx% Eff Htg Spt= xxx.x°F OATLock Diff= 1°F OATHtg Lock= 55°F Htg Status= _____ UnoccHtgDiff= 3.0°F UnoccHtg Spt= 55.0°F Space Temp= xxx.
McQuay IM 487-4 A Sub Menus (Continued) 4 End= mmm dd@hh:mm Tue= 00:00 - 00:00 Comp 3= xxxxx hr [2=1] Comp 4= xxxxx hr [2=1] Pos # 17-20= x.xxx Pos # 21-22= x.x Cond Fan2 Spt= 55°F Cond Fan3 Spt= 65°F Clg IntTime= 700 sec Htg IntTime= 500 sec Period= 60 sec Min DF Cap= 10% Min Strt Time= 120 sec Min Stop Time= 120 sec BSP Period= 5 sec PRAC= No Htg Propbd= 12.0°F Clg Propbd= 8.
B 104 Maximum Stages= 4 DH Stage Time= 10min Sensor Loc= Return Stage Time= 5 min Min Off Time= 20 min Min Exh On= 120 sec Hi Disch Alm= 170°F Lo Disch Alm= 40°F Hi Return Alm= 120°F [1=1 or 3] Airflow Switch= Off Dirty Filter= Off Alarm Name Alarm Type dd-mmm-yy hh:mm:ss Alarm Type dd-mmm-yy hh:mm:ss HtgB H/W= Off Alarm Name [3=8] [9=2] GenC H/W= Off Previous Alarm 3 [3<8] Ckt2 H/W= Off Previous Alarm 2 [3<8] Ckt1 H/W= Off Dirty FnlFltr= Off [20=1] Alarm Limits Alarm Type dd-mmm-yy hh:
Maintenance Maintenance Installation and maintenance must be performed only by qualified personnel who are experienced with this type of equipment and familiar with local codes and regulations. WARNING Moving machinery and electrical power hazards. Can cause severe personal injury or death. Disconnect and lock off all power before servicing equipment. CAUTION Sharp edges are inherent to sheet metal parts, screws, clips, and similar items. May cause personal injury.
Maintenance preventive compound. Pay close attention to fan shafts, sheaves, bearings, and bearing supports, Cabinet Sections Once a month, open a door on each section and verify that no moisture or debris is accumulating in the unit. Gas Furnace For information on maintenance of the gas furnace, refer to Bulletin No. IM 684 or IM 685. Bearing Lubrication CAUTION Cooling circuits The steps below are necessary only if the unit has been started. 1 Provide that each circuit is properly pumped down.
Maintenance Propeller Exhaust Setscrews For more information, see page 89. Setscrews are used to lock bearings, sheaves, locking collars, and fan wheels to their shafts. They must be checked periodically to see that they have not loosened. If this is not done, severe equipment damage could occur. Vibration Levels Each unit as shipped is trim balanced to operate smoothly. To provide satisfactory operation after shipping and installation, use accepted industry guidelines for field balancing fans.
Maintenance Figure 117. 24" DWDI backward curved wheel-to-funnel (036C, 040C) Figure 115. Return fan assembly U p p e r B e a r in g W h e e l .1 8 " .1 8 " F u n n e l F a n S h a ft F a n W h e e l 9 .3 1 " CL 9 .3 1 " F a n Figure 118.
Maintenance Figure 120. 44" and 49"SWSI airfoil wheel-to-funnel alignment W h e e l device with incorrect setpoint adjustment. Any other non-authorized trip point or setpoint adjustment voids all or portions of the unit’s warranty. Authorized setpoint adjustment is accomplished as follows 1 For motors with a 1.15 service factor, rotate the arrow on the dial to correspond to the motor FLA. See in Figure 121. 2 For motors with a 1.0 service factor, multiply the motor F u n n e l FLA by 0.
Maintenance Circuit Breaker Disconnect Circuit breakers are installed upstream of all VFDs to provide short circuit protection. The optional disconnect is a molded case switch with many of the same features of the circuit breaker. The disconnect comes standard with a through-the-door handle and mechanism to disconnect power to the unit prior to opening the door. The handle can be padlocked in the OFF position while performing maintenance to the unit.
Maintenance Terminals Phase Voltage Monitor (PVM) (see page 84) The terminals are spring clamp type. They only require inserting (see in Figure 124) and clamping the wire to be The phase voltage monitor is designed to protect three-phase loads from damaging power conditions. A microprocessorbased voltage and phase sensing circuit constantly monitors the three-phase voltages to detect harmful power line conditions.
Replacement Parts List Replacement Parts List Component designation Description McQuay part number MCB Main Control Board CCB1 Auxiliary Cooling Control Board (DX Circuit #1 or generic condenser) 060006101 112026101 (replaces 106102701) CCB2 Auxiliary Cooling Control Board (DX Circuit #2) 112026101 (replaces 106102701) EHB1 Auxiliary Electric Heat Control Board 112026101 (replaces 106102701) ERB1 Auxiliary Energy Recovery Control Board 112026101 (replaces 106102801) – RS-485 Communication
Service and Warranty Procedure Service and Warranty Procedure Replacement Parts When writing to McQuay for service or replacement parts, provide the model number, serial number, and unit part 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.
Limited Product Warranty (North America) Limited Product Warranty (North America) McQuay International (“Company”) warrants to contractor, purchaser and any owner of the product (collectively “Owner”) that Company, at its option, will repair or replace defective parts in the event any product manufactured by Company, including products sold under the brand names McQuay Air Conditioning, AAF Air Conditioning, AAF HermanNelson and McQuay Service, and used in the United States or Canada, proves defective in m
McQuay IM 487-4 115
116 McQuay IM 487-4
McQuay IM 487-4 117
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. This document contains the most current product information as of this printing. For the most up-to-date product information please go to www.mcquay.com.
