Installation and Maintenance Manual IM 777-1 Group: Applied Air Part Number: IM 777 Date: June 2005 Skyline¥ Air Handler Sizes 003–090 © 2005 McQuay International McQuay IM 782-1 1
Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 and maintenance must be performed by qualified personnel familiar with applicable codes and regulations and experienced with this type of equipment.
Installation Guidelines Service Clearances Figure 2: Service clearance for electrical power devices 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 Figure 8: Internal fastening A S p lic e C o lla r m u s t b e a lig n e d to s e a l to g a s k e t. R e m o v a b le L iftin g B r a c k e t 4 Check that the sealant is compressed between the mating Figure 7: Fasten bottom of section channels when the unit sections are joined. Touch up any places where gaps are noted. 5 After sections are seated tightly together, slip the splice cap over the top panel flanges.
Installation Guidelines Access Doors and Panels Figure 10: Opening fan section door For routine maintenance, access normally is obtained through access doors or by removing side panels. Removing all flat head fasteners along the sides of a panel allow it to be removed. Do Not Rotate Cup Fan and filter sections are always provided with a service door on one side of the unit. If requested on order, doors can be provided on both sides of the unit.
Installation Guidelines 3 Seal the double-wall panel on each side with an industrial/ commercial grade silicone sealant or duct seal compound. It is extremely important to seal each panel hole or penetration securely so it is airtight and watertight and there is NO EXPOSED FOAM INSULATION. WARNING Flame and smoke can cause equipment damage, severe personal injury, or death.
Installation Guidelines Dampers and Hoods Mounting Actuators Side dampers may be provided in the mixing box and economizer sections of units. When dampers are provided, a removable panel is located above the weather hood to provide access to the damper drive shaft. Other access may be available depending on the specific construction of the unit. See Figure 14. The installing contractor is responsible for the mounting of all field-installed actuators.
Installation Guidelines Piping Vestibules Piping and Coils For units that include a piping vestibule, cut the openings for routing the field piping as required in the field. Carefully seal passages cut through the panels to prevent air leakage. A single metal thickness pan is provided in the bottom of the curb-mounted vestibule. The pan can be removed if necessary. If holes are cut into the pan for a piping passage, seal the holes to prevent moisture leakage. See Figure 16.
Installation Guidelines Steam Coils (see Figure 18 on page 10) Valves Piping • Do not use modulating steam valves on high pressure systems. • 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. • When installing couplings, do not apply undue stress to the connection extending through unit panel.
Installation Guidelines Figure 18: 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. 1/4" petcock for continuous air venting High pressure float or bucket trap 12" min. 1" min. 12" min. High pressure bucket trap Full size of return conn.
Installation Guidelines Figure 19: 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. P re s s u re (P ) a t th e d r a in p a n 2 P 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 Figure 21: Removing shipping brackets On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment with a tie-down at each point of isolation. Before operating the unit: Remove the shipping brackets and tie-down bolts (see Figure 21) 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 • Electrical service to the fan must correspond to the rated voltage on the motor nameplate and conform to the National Electric Code and local restrictions. • Connect the fan section metal frame to the building electrical ground. • A door electrical interlock is not provided as standard. • Thermal motor protection is external to the unit.
Operation Guidelines Startup Checks 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. WARNING FIRE/ELECTRIC SHOCK HAZARD.
Operation Guidelines 7 Check alignment of fan and motor sheaves and belt tension. Adjust if necessary. Check tightness of sheave setscrews and/or capscrews. See Figure 35 and Figure 36 on page 24. 8 Leak test the thermal system to verify that connections are 3. To obtain dimension B, loosen screw and washer fasteners around periphery of funnel(s), shifting funnel radially as required, and re-torquing fasteners. Figure 24: Wheel-to-inlet funnel relationship—forward curved type fan wheels tight.
Operation Guidelines Figure 25: Wheel-to-inlet funnel relationship—plenum fans Figure 26: Wheel-to-inlet funnel relationship—inline fans Overlap Overlap Table 4: Wheel-to-inlet funnel relationship—plenum fans Table 5: Wheel-to-inlet funnel relationship—inline fans Wheel—funnel overlap 16 Wheel—funnel overlap Size Overlap 13.5 .120 Size Overlap 15 .190 16.5 .250 150 165 182 200 222 245 270 300 330 365 402 445 .375 .438 .562 .625 .688 .750 .812 .875 1.000 1.125 1.250 1.375 18.25 .
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 29: Torque for FC variable inlet vanes (in–lb) 300 250 2000 . 24 150 1500 Torque (in–lb) FC 200 Torque (in–lb) 50 .25 0 22 .0 20 FC C F 0 .0 0 18 .0 FC 15 FC Figure 30: Torque for AF variable inlet vanes (in–lb) 2 .6 12 FC 100 90 80 70 60 25 0. 4 AF 1000 900 800 700 600 500 400 350 300 250 200 0 .5 38 AF 00 3. 3 AF 00 0. 3 AF 00 0 .5 24 .25 0 AF F22 .0 A 20 F A 7. 2 AF 150 3000 49 54.
Operation Guidelines Fan Vibration Levels 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 10.
Service and Maintenance Periodic 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. 1 Motor bearings—All ball bearings are prelubricated and do not require additional grease at time of installation. However, periodic cleaning out and renewal of grease is necessary. Exercise extreme care to prevent foreign matter from entering the bearing.
Service and Maintenance passes around the sheave (pitch diameter). Calculate fan speed from the motor nameplate rpm. Fan rpm = motor rpm × Figure 32: VP type sheave adjustment A Measured diameter at motor sheave B Measured diameter at fan sheave VM and VP Variable Pitch Key Type Sheaves Mounting: E Single Groove 1 Mount all sheaves on the motor or driving shaft with the setscrews A toward the motor. D 2 Verify that both driving and driven sheaves are in alignment and that shafts are parallel.
Service and Maintenance the other flange. Determine this by accurately measuring the top width of the grooves. 9 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 operation. 7 Insert key F. 8 Tighten setscrews D and capscrews E. MVP Variable Speed Sheaves 9 Put on belts and adjust belt tension. Do not force belts over grooves.
Service and Maintenance 6 Tighten BOTH locking screws A in the outer locking ring 8 Do not loosen any screws other than the two locking screws A in the outer locking ring when adjusting the sheave pitch. before operating the drive. Use a torque wrench and tighten to the value shown in Table 14. Do not operate the drive until the locking screws have been set to the torque specifications. 7 Replace belts and adjust the motor base to tension the belts properly. See Figure 36.
Service and Maintenance Fan Drive Belt Adjustment General Rules of Tensioning 1 The ideal tension is the lowest tension at which the belt does not slip under peak load conditions. 2 Check tension frequently during the first 24 to 48 hours of operation. 3 Over tensioning shortens belt and bearing life. 4 Keep belts free from foreign material that can cause slippage. 5 Inspect V-drive on a periodic basis. Adjust tension if the belt is slipping. Do not apply belt dressing.
Service and Maintenance Table 15: 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 16: 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 To remove the fan assembly: 1 Remove the side panels and any intermediate supports Figure 39: Single coil installation/removal Opposite connection end Connection (follow instructions for side panel removal) end Coil 2 Once the panels and any intermediate supports are 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 4 Disconnect th
Service and Maintenance 7 Connect all piping and install the brass plugs for the vents and drains located in the connections. 8 Install the access panel. Removing and Installing Staggered Coils Staggered coils have two banks of coils positioned a few inches apart in the direction of airflow. Both coils are secured to the unit on the connection and opposite connection end of the unit. 1 Disconnect all piping and remove the brass plugs for the vents and drains located in the connections.
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 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. Enter the required information to expedite handling and prompt issuance of credits.
30 McQuay IM 777-1
McQuay IM 777-1 31
32 McQuay IM 777-1
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. © 2005 McQuay International • www.
