Installation and Maintenance Manual Maverick™ II Commercial Packaged Rooftop System Models MPS062E – 075E 62 to 75 Tons R-410A Refrigerant and MicroTech III® Unit Controller IM 991 Group: Applied Systems Part Number: IM 991 Date: June 2009
Contents Introduction .............................................................. 3 Unit Nameplate ................................................... 3 Compressor Nameplate...................................... 3 Gas Burner Nameplate ....................................... 3 Hazard Identification Information ........................ 3 Unit Description .................................................. 4 Refrigeration Piping ............................................ 6 Control Locations................
Introduction This manual provides general information about the McQuay Maverick III rooftop unit, model MPS 062E - 075E. 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 IM 684 or IM 685. Introduction The MicroTech III applied rooftop unit controller is provided.
Introduction Unit Description Typical Component Locations Figure 2 shows a typical gas heat or electric heat unit with the locations of the major components. Figure 3 on page 5 shows a typical cooling only 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: Typical Component Locations 1.
Introduction Figure 3: Component Locations 1.
Introduction Refrigeration Piping This section presents the unit refrigeration piping diagrams for the various available configurations.
Introduction Figure 6: Air Handler Piping (Flat DX) Legend 1 - Thermostatic expansion valve 2 - Distributor 3 - Hot gas bypass line Figure 7: Air Handler Piping (Staggered DX) Legend 1 - Thermostatic expansion valve 2 - Distributor 3 - Hot gas bypass line Liq u id lin e so le n o id v al v e 3 McQuay IM 991 7
Introduction Control Locations Figure 8 (gas and electric units) and Figure 9 on page 9 (cooling only and hot water heat units) show the locations of the various control components mounted throughout the units. See “Control Panel” on page 10 for the locations of control components mounted in control panels. Additional information is included in Table 2 on page 14 and the wiring diagram legend, which is included in “Wiring Diagrams” on page 40.
Introduction Figure 9: Control Locations—Cooling Only and Hot Water Heat Units Condenser section Supply fan discharge plenum section Heat section DX section C9 Filter section Economizer return air HP1-2, LP1-2 HTR1-2, U1/U2 HP3-4 (optional) HTR3-4 (optional) DAT OAE PC5 VM1 (optional) OAT ACT3 RAT ACT6 (optional) RAE (optional) SD2 (optional) McQuay IM 991 9
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. See “Wiring Diagrams” on page 40 for the legend and component description.
Introduction Figure 11: Typical Main Control Panel, 460 Volt McQuay IM 991 11
Introduction Figure 12: Typical Gas Heat Panel Figure 13: Typical Prop Exhaust Panel, 2 Fans, 460 Volt IT TD10 R22 TB11 R20 AS R23 R21 LS2 LS1 S3 FSG FSG Time Figure 14: Condensing Unit Control Panel 12 McQuay IM 991
Introduction Figure 15: Electric Heat Panel Figure 16: Harness Plug Connector Detail FB33 M33 FB32 M32 FB31 M31 FB43 FB42 FB41 M42 M43 M41 RATS DATS OATS FP1 EPTS OPEN1 H53 AFD10 AFD20 SV12 SV56 ACT3 OPEN2 TB11 OAE PC5 PC7 GLG3 HL22 OPEN3 GSHT1 GSHT2 SD1 SD2 DS3 DFRH McQuay IM 991 DFLH OPEN4 COMP1 COMP2 COMP3 COMP4 COMP5 COMP6 LT10 LT11 LT OP1 LT OP2 13
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 Table 2: Controls, Settings, and Functions (continued) Symbol Description Function Reset Location Setting Range Differential Part no. SPS2 Static pressure sensor duct #2 Converts static pressure signals to voltage signals N/A Main control box N/A 0–5" w.c. (0–1245.4 Pa) 1–6 V (dc) out N/A 049545007 Static pressure sensor: building (space) pressure Converts static pressure signals to voltage signals. N/A Main control box N/A -025–0.25" w.c. (-62.3–62.
Introduction Condenser Fan Arrangement Table 4 below shows the condenser fan numbering conventions and locations for each unit size.
Mechanical Installation The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and all applicable codes. It is the responsibility of the installer to determine and follow the applicable codes. Mechanical Installation Note: Low head pressure may lead to poor, erratic refrigerant feed control at the thermostatic expansion valve.
Mechanical Installation Ventilation Clearance Below are minimum ventilation clearance recommendations. The system designer must consider each application and provide adequate ventilation. If this is not done, the unit will not perform properly. Unit(s) surrounded by a screen or a fence: 1 The bottom of the screen or fence should be at least 1 ft. (305 mm) above the roof surface. 2 The distance between the unit and a screen or fence should be as described in “Service Clearance” on page 17.
Mechanical Installation 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.
Mechanical Installation Figure 19: Roof Curb Assembly 61.0 [1549 mm] - MPS 062E only or 74.0 [1880 mm] - MPS 070E - 075E only Using remaining side supports in this area, align lengths on opposite sides of assembly and install a cross support at each side. Condenser Section Support 6.8 [173 mm] 1.5 [38 mm] 28.0 [711 mm] Cap 76.0 [1930 mm] Inside Equal Length Side Supports 7.5 [191 mm] Supply Air 2.0 [51 mm] 8.8 [224 mm] 38.0 [965 mm] Inside 3.5 [89 mm] 38.
Mechanical Installation Figure 20: Typical Power Wire Entrance, Curb View (See Project Certified Drawings) 6.8 [173 mm] 1.5 [25 mm] 87.0 [2210 mm] 28.0 [711 mm] 38.0 [965 mm] SA OPNG RA OPNG 1.5 [25 mm] See Detail B 2 Typ 4 Typ 8.8 [223 mm] 61.0 [1549 mm] - MPS 062E only or 74.0 [1880 mm] - MPS 070E - 075E only 1.5 [25 mm] 81.0 [2057 mm] 7.5 [191 mm] Air handler length minus 6.4 [163 mm] 8.0 [203 mm] 12.1 [307 mm] 5.1 [130 mm] 0.9 [23 mm] Dia. K.O. 3.0 [76 mm] Dia. K.O. 3.
Mechanical Installation Post and Rail Mounting When mounting by post and rail, run the structural support the full length of the unit. Locate the structural member at the base of the unit as shown in Figure 21, assuring the I-beam is well supported by the structural member. CAUTION The unit must be level side to side and over the entire length. Equipment damage can result if the unit is not level.
Mechanical Installation Lifting Points Refer to Figure 23 and the following calculations to determine whether a four or six point lift is required. X = distance from the entering air end of the unit (or shipping section) to the first lifting lug in the direction of air flow. Note: Middle lifting lug may be installed on either side of the midpoint to avoid interference with condensate drains.
Mechanical Installation Unit Piping Condensate Drain Connection The unit is provided with a 1.5" male NPT condensate drain connection. Refer to certified drawings for the exact location. For proper drainage, level the unit and drain pan side to side and install a P-trap. RPS units may have positive or negative pressure sections. Use traps in both cases with extra care given to negative pressure sections. In Figure 24, dimension “A” should be a minimum of 8" (203 mm).
Mechanical Installation Hot Water Coil Piping Hot water coils are provided without valves for field piping or piped with three-way valves and actuator motors. Figure 25: Hot Water Heat Section (Shown with Factory Valve and Piping) Note: All coils have vents and drains factory installed. Hot water coils are not normally recommended for use with entering air temperatures below 40°F (4°C). No control system can guarantee a 100% safeguard against coil freeze-up.
Mechanical Installation Damper Assemblies Figure 27: Damper Adjustment 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-installed 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.
Mechanical Installation Intake Hood Damper (0% to 30% outside air) Figure 28: Damper Linkage Bar Typical for All Sizes These dampers are intended to remain at a fixed position during unit operation, providing fresh air quantities from 0 to 30% of the total system airflow, depending on the damper setting. This setting is made at the linkage rod on units with manually adjustable linkages. On units provided with MicroTech III controls, the damper position may be set at the controller keypad.
Mechanical Installation 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. Recaulk field-assembled options such as external piping or vestibules per the installation instructions provided with the option.
Mechanical Installation Installing Duct Static Pressure Sensor Taps Figure 30: 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 10). Carefully locate and install the duct static pressure sensing tap.
Mechanical Installation 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 Field Power Wiring Figure 32: Power Wiring Connections Electrical Installation Wiring must comply with all applicable codes and ordinances. The warranty is voided if wiring is not in accordance with these specifications. An open fuse, tripped circuit breaker, or Manual Motor Protector (MMP) indicates a short, ground, or overload. Before replacing a fuse, circuit breaker, MMP, or restarting a compressor or fan motor, identify the trouble and correct.
Electrical Installation Figure 34: Typical Power Wire Entrance, Unit View (Actual Opening Shown on Submittal Documents) All Units The minimum circuit ampacity (wire sizing amps) is shown on the unit nameplate. Refer to Table 5 on page 33 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.
Electrical Installation In compliance with the National Electrical Code, an electrically isolated 115V circuit is provided in the unit to supply the factory mounted service receptacle outlet and optional unit lights. This circuit is powered by a field connected 15A, 115V power supply. Leads are brought into the units through a 7/8" knockout in the bottom of the main control panel, near the power wire entry point.
Preparing Unit for Operation Adjusting Spring Mounts Preparing Unit for Operation Spring Isolated Fans Figure 39: Spring Mount 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 37: RDT Spring Mount Hold Down Fasteners Hold-down fasteners To adjust spring mount compression, perform the following: 1 Loosen the .625-18 UNF hex nut.
Preparing Unit for Operation Relief Damper Tie-Down Economizer sections with a 30" or 40" return fan have a relief damper that is tied down for shipping. Remove the two brackets and two screws before operation to allow movement of dampers. Access is from inside the economizer section. Adjustment of Seismic Restraints Spring mounted supply air and return air fans may be ordered with factory installed seismic restraints. Refer to Figure 40.
Sequences of Operation Sequences of Operation The following sequences of operation are for a unit equipped with MicroTech III, an economizer, 4-compressor/4-stage cooling, 3 to 1 turn down burner, variable frequency drives (VFD), and an external time clock. These sequences describe the ladder wiring diagram logic in detail; refer to “Wiring Diagrams” on page 40 as you read them. Note that your unit’s sequences of operation may vary from those described here.
Sequences of Operation Mechanical Cooling Operation 4-Compressor/4-Stage Unit satisfied, then M1 compressor contactor is energized to bring on compressor 1 on refrigerant circuit 1 (line 708 - 710, Figure 49 on page 46. The M1 auxiliary brings on: Refer to Figure 61 on page 58. In this configuration there are four equally sized compressors and two cooling circuits. In the following description, compressor #1 is lead.
MicroTech III Controller Operation Using the Keypad/Display MicroTech III Controller Operation The keypad/display consists of a 5-line by 22 character display, three keys and a “push and roll” navigation wheel. There is an Alarm Button, Menu (Home) Button, and a Back Button. The wheel is used to navigate between lines on a screen (page) and to increase and decrease changeable values when editing. Pushing the wheel acts as an Enter Button.
MicroTech III Controller Operation Figure 44: Password Entry Page Enter Password 1/1 Enter Password **** Entering an invalid password has the same effect as continuing without entering a password. Once a valid password has been entered, the controller allows further changes and access without requiring the user to enter a password until either the password timer expires or a different password is entered. The default value for this password timer is 10 minutes.
Wiring Diagrams Legend Wiring Diagrams ID ACT3, 4 ACT10, 11 ACT12 AFD10 AFD20 AS BM CB10 CB20 CCB1, 2 CPC CPR CS1, 2 DAT DHL DS1 EFT EHB1 F1A, B F1C F2 F3 FB31–40 FB41–50 FD FLC FSG GCB1 GRD GV1 GV2 GV3 HL1–10 HL11–20 HL22 HL23 HL31–40 HL41–50 40 ID Description Actuator motor, economizer Actuator motor, exhaust dampers Actuator motor, enthalpy wheel bypass damper Adjustable frequency drive, supply fan Adjustable frequency drive, return/exhaust fan Airflow switch, burner blower Burner blower motor Circui
Wiring Diagrams ID R25 R26 R28 R29 R66 R67 R69 RAE RAT REC1 REC2 REC3 S1 S2 S3 S7 SD2 SPS1, 2 SR1-3 SV1, 2 T1 T2 T3 T4 T5 T9 TB1 TB2 TB3 Description Relay, heat, gas, start supply fan inverter Relay, isol/exh. dampers, open/close Relay, isolation damper, safety Relay, remote fire alarm Relay, smoke detector, return air Relay, supply fan, enable Relay, Inv.
Wiring Diagrams Figure 45: VAV Fan Power, Unit Powered Receptacle 42 McQuay IM 991
Wiring Diagrams Figure 46: VAV Fan Power, Unit Powered Receptacle (Continued) McQuay IM 991 43
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 T2 T3 GLG1 L2 L3 G T2A T2B T3A T3B L2B L3A L3B T1B L1B L2A T1A L1A 426 MMP10 T1 L1 DS1 139A 138A 137A 426 T3 T2 T1 (Schematic continues on next page.
McQuay IM 991 170 169 168 167 166 165 164 163 162 161 168A /2.00 /8.00 T1_115VAC 109 L3-1 L2-1 L1-1 PB11 164 162 TB1A 1 2 3 4 1 1 1 F1C F1B F1A 2 2 2 168B 164A 162A H1 X3 H2 X2 H3 X1 H4 T1 TB1A GRD 5 6 7 8 (Schematic continues on the previous page.) T1_N 168C /2.00 /3.00 /4.00 /8.
Wiring Diagrams Figure 49: RPS 75 Condensing Unit Power 46 McQuay IM 991
Wiring Diagrams Figure 50: RPS 75 Condensing Unit Power (Continued) McQuay IM 991 47
Wiring Diagrams Figure 51: VFD Control 48 McQuay IM 991
Wiring Diagrams Figure 52: VFD Control (Continued) McQuay IM 991 49
Wiring Diagrams Figure 53: VAV Control Inputs 50 McQuay IM 991
Wiring Diagrams Figure 54: VAV Control Inputs (Continued) McQuay IM 991 51
Wiring Diagrams Figure 55: Constant Volume Control Inputs 52 McQuay IM 991
Wiring Diagrams Figure 56: Constant Volume Control Inputs (Continued) McQuay IM 991 53
Wiring Diagrams Figure 57: Gas Burner Control 54 McQuay IM 991
Wiring Diagrams Figure 58: Gas Burner Control (Continued) McQuay IM 991 55
Wiring Diagrams Figure 59: Electric Heat Control 56 McQuay IM 991
Wiring Diagrams Figure 60: Electric Heat Control (Continued) McQuay IM 991 57
Wiring Diagrams Figure 61: Condensing Unit Control with Scroll Compressors 58 McQuay IM 991
Wiring Diagrams Figure 61: Condensing Unit Control with Scroll Compressors (Continued) McQuay IM 991 59
Wiring Diagrams Figure 62: CV Fan Control /3.11 115VAC_GF/1 T3_24V 207 SRC MMP10 11(31) 9-16 24V SRC 1NO 207 SUPPLY FAN SOURCE 9-16 WIRED INTERNAL TO MOTHERBOARD jprs 24V SRC R68 404A 2 2NO 207 RETURN FAN MMP20 426A 11(31) 12(32) 2 R67 426B 12(32) /1.68 T1_N 10 2 MCB BO2 /3.
Unit Options Control Actuators Unit Options The actuators are controlled by an analog signal from the unit controller. Damper actuators utilize a 0-10 V (dc) analog signal while modulating heating/cooling valve actuators utilize a 2-10 V (dc) signal. Spring-return actuators are used for the 0 - 30% outdoor air and economizer dampers. The mixing dampers are normally closed to the outside air. Figure 64: Control Actuators Wiring Diagram Enthalpy Control Figure 65: Enthalpy Control Settings 8 5 9 0 (2 9 .
Unit Options Differential Enthalpy Control (OAE/RAE) Smoke and Fire Protection An optional electric differential enthalpy control arrangement (OAE/RAE) is available on units with MicroTech III control. In this configuration a solid-state humidity and temperature sensing device is located in both the return (RAE) and outside intake (OAE) airstreams. This OAE device has the same A through D scale as the device described above.
Unit Options External Time Clock or Tenant Override There are several methods of switching the rooftop unit between occupied and unoccupied operation. It can be done by the controller internal schedule, a network schedule, an external time clock, or a tenant override switch. If the internal schedule or a network schedule is used, field wiring is not required.
Unit Options VAV Box Output The VAV Box Output (MCB-DO10) supplies 24 V (ac) to terminal 116 on the field terminal block (TB2) when the output is on. To use this signal, wire the coil of a field supplied and installed 24 V (ac) pilot relay across terminals 116 and 117 on TB2. When this output is on, 24 V (ac) is supplied from the T3 control transformer through the output relay to energize the field relay. Refer to the as-built wiring diagrams.
Unit Options Convenience Receptacle A Ground Fault Circuit Interrupter (GFCI) convenience receptacle is provided in the main control box on all units. One of the following is required: 1 Connect a separate field-supplied 115 V power wiring circuit to the 115V field terminal block TB7, located in the main control box. The VFDs and pressure transducers are located in the control box mounted in the condensing section.
Unit Options Variable Frequency Drive Operation Refer to the vendor instructions supplied with the unit. Propeller Exhaust Fan Option 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.
Unit Options Moving the weight stack along the length of the mounting bracket slot (Figure 73) will effect the full open balance of the blade assembly. Moving the weights further away from the blade pivot point will cause the blades to become more balanced so that at some point, and with enough weight, the blades would remain open. Care must be taken to ensure that when the weights are moved outward from the blade pivot point they will not interfere with the adjacent blade when the blades close.
Unit Options Figure 76: Propeller Exhaust Fan Replacement Parts List 1 2 9 1. Fan panel 2. Propeller 3. Drive frame channe l (2) 4. Motor plate 5. Motor 6. Motor pulley 7. Shaft pulley 8. Fan shaft 9. Bearings 10. Belt 11. Bearing plate 8 7 10 4 3 6 5 11 Table 7: Propeller Exhaust Fan Troubleshooting Problem Reduced Airflow Excessive Noise Cause System resistance is too high. Unit running backwards. Fan speed too low. Excessive dirt on propeller.
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, or complete the “Rooftop Equipment Warranty Regist. Form” on page 98 and return it to McQuay International.
Check, Test, and Start Procedures Fan Start-up 1 Verify all duct isolation dampers are open. Unit mounted isolation dampers may be mounted in the supply or return sections. 2 Place the unit into the Fan Only mode through the keypad menu System Summary\System\Ctrl Mode= Fan Only. 3 Turn Switch S7 to ON. The controller should enter the Startup Initial operating state. If the fan does not run: a Check fuses F1 and F3. b Check the manual motor protectors or that the circuit breakers have not tripped.
Check, Test, and Start Procedures Figure 77: Condenser Fan Blade Positioning economizer must fully open before the controller will energize mechanical cooling. 5 When the outdoor air damper has fully opened and the time delay has expired, the liquid line solenoid SV1 and the compressor should start. 1.21" a Verify that there is a call for cooling by checking the keypad menu System Summary \ System \ UnitStatus=. This should be in Cooling.
Check, Test, and Start Procedures 10 Check the oil level in the compressor sightglass. If low oil or heavy foaming is observed, it is possible that liquid refrigerant is returning to the compressor. Check the suction superheat (see “Expansion Valve Superheat Adjustment” on page 72). It should be between 10°F (5.5°C) and 13°F (7.2°C). 11 Open S1. the compressor should stop. Place the unit into the “Fan Only” mode through the keypad menu System Summary \ System \ Ctrl Mode= Fan Only.
Check, Test, and Start Procedures Air Balancing Figure 78: Sheave Alignment (Adjustable Shown) Air balancing should be performed by a qualified air balancing technician. Note that the supply fan motors are usually shipped with variable pitch sheaves which are typically set at the low end of the drive’s fan rpm range. See “Mounting and Adjusting Motor Sheaves” on page 74. The return fan motors are usually shipped with fixed pitch sheaves.
Check, Test, and Start Procedures Figure 79: Drive Belt Adjustment D e fle c tio n = Adjusting: 1 Slack off all belt tension by moving the motor toward the B e lt S p a n 6 4 driven shaft until the belts are free from the grooves. For easiest adjustment, remove the belts. B e lt S p a n 2 Loosen setscrews B and C in the moving parts of the sheave and pull out external key E (see Figure 80). This key projects a small amount to provide a grip for removing.
Check, Test, and Start Procedures 2 Loosen both locking screws A in outer locking ring, but do Adjusting: not remove them from the sheave. There is a gap of approximately 1/2" (1 mm) between the inner and outer locking rings. This gap must be maintained for satisfactory locking of the sheave. If locking screws A are removed by accident and the gap is lost, screw the outer locking ring down until it touches the inner locking ring.
Check, Test, and Start Procedures Figure 82: MVP Variable Pitch Sheaves (Type A-B) C e n te r F la n g e s G a p O u te r L o c k in g R in g L o c k in g S c re w s "A " In n e r L o c k in g R in g S p a n n e r W re n c h H o le 3 C a p s c re w s "B " Figure 83: MVP Variable Pitch Sheaves (Type A–B) B a r r e l F la n g e E n d F la n g e B a rre l 1 8 ° 2 L o c k in g S c re w s "A " L o n g K e y H e re 76 S h o rt K e y H e re T h re a d C e n te r F la n g e A s s e m b ly McQuay IM 991
Final Control Settings When all start-up procedures are completed, set the controls and program the MicroTech III controller for normal operation. Use the following list as a guide; some items may not apply to your unit. For more detail, see IM 919 and OM 920. Final Control Settings 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).
Final Control Settings Figure 84: Keypad Accessible Menu Structure 78 McQuay IM 991
Final Control Settings Figure 85: Keypad Accessible Menu Structure (Continued) McQuay IM 991 79
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. Maintenance WARNING Moving machinery and electrical power hazards. May 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 Cabinet Sections Evacuation Once a month, open a door on each section and verify that no moisture or debris is accumulating in the unit. Use a vacuum pump with a pumping capacity of approximately 3 cu.ft./min. and the ability to reduce the vacuum in the unit to at least 1 mm (1000 microns). Cooling Circuits 1 Connect a mercury manometer or an electronic or other The steps below are necessary only if the unit has been started.
Maintenance Table 9: Pressure-Vacuum Equivalents Absolute pressure above zero Vacuum below 1 atmosphere Microns PSIA Mercury (mm) Mercury (in.) 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 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 14.697 760.00 759.95 759.90 759.85 759.80 759.70 759.50 759.00 758.00 756.00 754.00 752.00 750.00 745.00 740.00 730.00 710.
Maintenance Subcooling 1 Remove and clean upper and lower grease plugs. When field charging the unit, use the following to properly charge the unit: 2 Insert a grease fitting into the upper hole and add clean • All compressors on each circuit operating at full capacity. 3 Run the motor for five minutes before replacing the plugs. • Allowable subcooling ranges are between 13°F to 20°F. • Be sure to measure pressure and temperature at the same location when finding/calculating subcooling.
Maintenance Bearing Replacement CAUTION The tables below state general lubrication recommendations based on our experience and are intended as suggested or starting points only. For best results, specific applications should be monitored regularly and lubrication intervals and amounts adjusted accordingly. The following instructions must be read in entirety before attempting installation or removal. The procedures indicated should be carefully followed.
Maintenance Propeller Exhaust Fan 2 Check bearing collar, sheave, and wheel hub setscrews, See “Propeller Exhaust Fan Option” on page 66. 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. See Table 17. Note: Excessive vibration from any cause contributes to premature fan and motor bearing failure.
Maintenance Figure 86: DWDI Airfoil Wheel-to-Funnel Alignment Figure 89: Oil Equalization Line Table 19: DWDI Airfoil Wheel-to-Funnel Relationship Wheel-to-funnel relationship (in inches) Wheel diameter (inches) A +0.3/ — 0.0 30 33 10.6 (269 mm) 11.7 (297 mm) Figure 87: 40" SWSI Airfoil Wheel-to-Funnel Alignment W h e e l b The TPTL line connects to each compressor with “rota- lock” fittings (Figure 90).
Maintenance 3 Discharge Line a This is the tubing that connects near the top of the compressor. Figure 92: Discharge Tubes 4 Braze couplings on the cut end of the original tubes so that they fit snugly into place. 5 Replace the TPTL oil equalization line. 6 Cut the new suction and discharge tubes to fit between the compressor and the couplings. 7 Assemble the new tubes but do not braze until everything fits snugly. 8 Braze tubes into place. Alternative Replacement 1 Drain the oil.
Maintenance All-Aluminum Condenser Coils Connecting the Condenser Coil to Copper Tubing The condenser coils are an all-aluminum design including the connections, micro-channels, fins (an oven brazing process brazes the fins to the micro-channel flat tube), and headers (Figure 93), which eliminates the possibility of corrosion normally found between dissimilar metals of standard coils. Figure 94 and Figure 95 show the aluminum condenser coil connection(s) to the copper tubing in the unit.
Maintenance Refrigerant Charge Servicing Refrigerant Sensors or Switches The unit nameplate references proper charge for each refrigerant circuit in case a full charge must be added to the unit. Verify these values using pages Table 8 on page 81. The McQuay Rooftop unit includes the following refrigerant sensors or switches. The micro-channel condenser requires much less charge than traditional fin tube condensers.
Maintenance Control Panel Components Figure 96: Manual Motor Protector Manual Motor Protector (MMP) The manual motor protector (MMP) provides coordinated branch circuit, short circuit protection, a disconnecting means, a motor controller, and coordinated motor overload protection. A short circuit indicator with manual reset is mounted along side of each MMP as a means to differentiate between a short circuit and overload trip conditions. The MMP trip points are factory set.
Maintenance Field Wiring Terminals WARNING In certain applications the circuit breaker may be mounted upside down. Therefore, when the handle is in the DOWN position it may not be turned OFF. The handle position corresponds to ON and OFF text clearly printed on the face of the unit. Be sure the mounting orientation and desired handle position is verified prior to performing service on the equipment. Only qualified service personnel should work on this equipment.
Maintenance d Test rotate the handle to insure that power “lockout” is Disconnect provided. DANGER Hazardous voltage. Will cause severe injury or death. Disconnect electric power before servicing equipment. More than one disconnect may be required to de-energize the unit. The optional disconnect is a “through-the-door” molded case switch with similar features of the circuit breaker.
Maintenance Troubleshooting Pressure Transducers Use the following procedure to troubleshoot a suspect sensor: If the duct static pressure always reads 0" WC on the unit keypad/display and the VFD speed is continuously ramping to 100%, check the following: Check the 24 V (dc) power supply to the sensor, verify that there is 24 V (dc) between the suspect transducer “+” and “-” terminals. Using an accurate manometer or gauge, measure the same pressure that the suspect transducer is sensing.
Replacement Parts List MicroTech III Unit Controller Parts Replacement Parts List McQuay Part # Aftermarket Part Description 193407301 193407401 193407501 193407601 193407701 193408001 TBD 193408101 193408201 193408301 193408401 193408501 193408601 193408701 193408801 193408901 193409001 193409101 193409201 193409301 193409401 193409501 193409601 193409701 193409801 193409901 193410001 193410101 193410201 193410302 193410303 193410304 193410305 193410306 193410307 193410308 MT3006 LG CONTROLLER W/HMI 27
Service and Warranty Procedure Replacement Parts Replacing a Portion of a Tandem or Trio 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.
Service and Warranty Procedure On McQuay equipment that includes the extended 2nd -5th year compressor warranty option, the replacement compressor must be ordered through the McQuay Parts Department (Minneapolis). 1 Contact the McQuay Parts Department for compressor availability. 2 Send the McQuay Parts Department a completed parts order form. 3 The Parts Department will process the order and the compressors will be shipped from our Dayton, OH warehouse via ground transportation.
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 material or workmanship within twelve (12)
Rooftop Equipment Warranty Regist. Form Rooftop Equipment Warranty Regist. 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 RoofPak roof mounted air conditioners with or without heat recovery and roof mounted air handlers. Job Name: _______________________________________________________________________ McQuay G.O. No.
Rooftop Equipment Warranty Regist. Form Warranty Registration Form (continued) E. Ambient temperature ______________________ °F F. Compressor lockout timers function? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A G. Does unit start up and perform per sequence of operation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A Yes No N/A L.
Rooftop Equipment Warranty Regist. Form Warranty Registration Form (continued) VI. GAS BURNER CHECK, TEST, & START Specifications: Refer to IM 684 Modulating Forced Draft Gas Fired Furnace A. (Gas) Furnace model no. _____________________ B. (Gas) Burner model no. _____________________ Serial no. ___________________ C. (Gas) Type firing: _________Stage 2 _________Stage Modulation _________Single D. (Gas) Rated firing rate: ________________ MBH input E. (Gas) Altitude: ______________________ ft.
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.
