Installation and Maintenance Manual Skyline™ Air Handler IM 777-7 Group: Applied Air Systems Part Number: IM 777 Date: November 2011 Models OAC/OAH 003G – 090G © 2011 McQuay International
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 19 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . 3 Before Starting the Unit . . . . . . . . . . . . . . . . . . . . . . 19 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . .
Introduction General Information Receiving and Handling Introduction 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.
Introduction Unit Storage Belt driven fans: • Store on a level surface in a clean, dry location where temperature can be controlled if possible. • Reduce belt tension by at least 50% or remove the belts. Remove belts if they will be subjected to temperatures exceeding 85° F to avoid deterioration. • Pack fan and motor bearings (unless motor bearings are sealed) with compatible grease with the shaft stationary. After grease has been installed, rotate shaft about 10 rotations.
Mechanical Installation Service Clearances Rigging 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. Provide sufficient space—at least equal to the length of the coil—on the side of the unit for coil removal.
Mechanical Installation If the unit is supported on rails they must be placed around the entire perimeter. Additional Supports must be placed perpendicular to airflow spanning the full width of the unit at all shipping splits. If the unit is over 107” wide these supports must also be placed at the entering and leaving edges of fan and cooling coil sections. The perimeter rails must be at least 2” wide at the top and capable of carrying the entire weight of the unit.
Mechanical Installation d A length of “D” gasket is attached to each section (Figure 7). This gasket MUST be installed to the unit base section. Figure 10: D-Gasket Placement Detail (Skyline Plus Units Only) IMPORTANT The gasket is to be installed in an arc shape with the ends lower than the center, so that any moisture that may reach the gasket will be drained to the outside of the unit.
Mechanical Installation Panels, Frame Channels, and Doors Panel Removal To remove a side or top panel, remove the flat head Torx 30 fasteners along the sides of the panel. Lift off the panel after removing all fasteners. Frame Channel Removal Frame channels that run the length of the unit along the top can be removed to allow access to both the side and top of the unit. To remove the frame channel, first remove the side panel(s).
Mechanical Installation Injected-Foam Insulated Panels Skyline air handlers now are furnished with double-wall, injected-foam insulated panels. Foam panels are stronger, more rigid, and lighter than panels with fiberglass insulation. The insulation R-value is improved to 13. However, foam insulation can burn when exposed to flame or other ignition sources and release toxic fumes. Take care in cutting and sealing all field-cut openings in these panels.
Mechanical Installation If the unit has a top mixing box or economizer damper or a top duct connection, field fabricate and install flashing to divert moisture from the connection. The flashing must lap over the standing seams of the top panels. The flashing also must lap over the side edges of the unit (Figure 16).
Mechanical Installation Face and Bypass Section Mounting Internal and external face and bypass sections are mounted together using the instructions for horizontal components and do not require additional instruction. Skyline air handlers are provided with a bypass duct that is integral to the unit construction and requires no field assembly. For units with standard base rails, the vestibule is open to the coil section; therefore, seal all holes to prevent air leakage.
Mechanical Installation Direct Expansion Coils • The coil distributor and suction connection extend through the end panel of the coil section. • Check nozzle in distributor for proper tonnage. • When a (field supplied) thermostatic expansion valve is located outside the unit and connected directly to the distributor (except on units with piping vestibules). Do not apply heat to the body of the expansion valve. • The thermostatic expansion valve must be the external equalizer tube type.
Mechanical Installation Figure 21: Piping Arrangements Float and thermostatic trap Check Valve Strainer Control valve modulating two position Gate Valve High Pressure (over 25 psi) Vacuum breaker 1/2" check valve Steam main Vacuum breaker 1/2" check valve 1/4" petcock for continuous air venting Steam main Return main 1" min. 12" min. 1/4" petcock for continuous air venting High pressure float or bucket trap 1" min. 12" min. High pressure bucket trap Full size of return conn.
Mechanical Installation Water Heating Coils Figure 22: Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet CAUTION Improper installation, use, or maintenance of water heating coils can cause equipment damage. Read and follow instructions carefully. Pressure (P) at the drain pan 2P ATTENTION Si l’installation, l’utilisation ou l’entretien des serpentins de chauffage à eau sont inadéquats, ceci endommagera l’équipement. Lire et suivre attentivement les instructions.
Mechanical Installation Internal Isolation Assembly Adjustment On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment. with a tie-down at each point of isolation. Before Operating the Unit: For models 040 through 090 with housed fans, the isolators should be at equal height during fan operation (6"). Center the fan outlet in the outlet panel opening. If adjustment is required, loosen the cap screw on top of the isolator assembly.
Mechanical Installation Figure 25: Removing “Motor Behind” Shipping Brackets Figure 26: Removing “Motor Beside” Shipping Brackets Unit sizes 006 - 090 Unit sizes 006 - 090 S h ip p in g h o ld d o w n r e m o v e a n d d is c a r d ( T y p ic a l 4 p la c e s ) S h ip p in g b r a c k e t r e m o v e a n d d is c a r d ( T y p ic a l 4 p la c e s ) S e e d e ta il " A " S p r in g h e ig h t a d ju s tm e n t s c r e w D im "H " P O S 2 P O S 3 M o to r A ir flo w F a n P O S 1 P O S 4 F a n is o
Electrical Installation Wiring Electrical Installation Figure 28: Electrical Conduit Location DANGER Capacitor hazardous voltage! Failure to disconnect power and discharge capacitors before servicing will result in serious injury or death. Disconnect all electric power (including remote disconnects) before servicing. Perform lockout/tagout procedures to ensure that power can not be energized.
Electrical Installation • Control wiring—access to the VFD is through the fan cabinet access door for single fans. Provide shielded cable only as described in the VFD manual provided with the unit. Route wire through panel so that it not interfere with any other components or in the way of any access doors. Do not drill through drip or drain pans. Refer to the VFD installation manual provided with the unit for detailed control wiring instructions.
Operation Guidelines Startup Checks Operation Guidelines When performing startup and service, always take thorough safety precautions. Only trained, experienced personnel should perform these functions. WARNING Rotating fan. Can cause severe injury or death. Before servicing fans, lockout and tag out power. AVERTISSEMENT Ventilateur en rotation. Peut causer des blessures sévères ou même la mort. Avant d’effectuer l’entretien des ventilateurs, bloquer et couper la tension.
Operation Guidelines 12 If multiple fans are supplied with isolation dampers, make sure the isolation dampers are fully open before starting the fans. Fan Wheel Alignment Figure 29: Wheel-to-Inlet Tunnel Relationship—Airfoil Type Fan Wheels (Housed) VFD Setup Fans ordered with VFDs that were factory installed are setup and tested prior to shipment. Prior to starting the fan(s), double check the VFD settings according to the recommendations in the VFD manual.
Operation Guidelines Figure 31: Wheel-to-Inlet Funnel Relationship—13 to 36 Belt-Drive Plenum Fans Figure 32: Wheel-to-Inlet Funnel Relationship—40 to 60 Belt-Drive Plenum Fans Cross Section Reference Cross Section Reference EQUALLY SPACED AROUND DIAMETER B A FUNNEL END TO FAN WHEEL OPENING FROM FUNNEL END TO FANWHEEL OPENING END A EQUALLY SPACED AROUND DIAMETER B C Table 8: Wheel-to-Inlet Funnel Relationship—13 to 36 BeltDrive Plenum Fan Wheel-Funnel Parameters C Size A B C 13 0.25 0.
Operation Guidelines Setscrews on MPQ fan wheels must be installed using a calibrated torque wrench to the value listed below, ±5%.The fasteners must be periodically checked to satisfy agency requirements for components on rotating machinery. Table 10: Setscrew Torque Specifications—Class II Plenum Fans Only Fan Size Setscrew Size Torque (ft.-lb) Aluminum Steel 11/12/13 3/8 19.2 N/A 15 3/8 19.2 N/A 16 3/8 19.2 N/A 18 3/8 19.2 N/A 20 3/8 19.2 N/A 22 3/8 19.2 N/A 24 3/8 19.
Operation Guidelines Operating Limits Do not exceed the operating limits in Table 15 through Table 19. 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 15: Unit Sizes 003 to 035 Fan operating limits Forward curved—housed Diameter Maximum rpm Class I Maximum rpm Class Il Airfoil—housed Diameter Maximum rpm Class I Maximum rpm Class Il 9×4 N/A 2700 9×7 2189 2854 9×9 2223 2896 10.
Operation Guidelines Fan Vibration Levels Vibration Causes 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 20. Table 20: Vibration Levels Note: Fan speed (rpm) Vibration 800 or less 5 mils maximum displacement 801 or greater 0.20 in/sec. maximum velocity Excessive vibration from any cause contributes to premature fan and motor bearing failure.
Service and Maintenance Periodic Maintenance Fan Shaft Bearings Service and Maintenance 1 Check all moving parts for wear every six months. 2 Check bearing collar, sheave, and wheel hub setscrews, sheave capscrews, and bearing hold-down bolts for tightness every six months. 3 Annually check and snug all electrical connections. Inspect for signs of water damage such as corrosion and repair if necessary. Check ground conductor and connection integrity. Service if needed.
Service and Maintenance Table 23: Recommended Lubricants for Fan Shaft Ball Bearings Name Temperature Base Thickener NLGI grade Texaco, Premium RB Mobile, AW2 30° to 350°F (34° to 177°C) 40° to 437°F (40° to 175°C) 68° to 356°F (50° to 180°C) 60° to 450°F (51° to 232°C) Parafinic mineral oil Mineral oil Lithium 2 Lithium 2 Synthetic Lithium 2 Synthetic Lithium 2 40° to 300°F (40° to 149°C) Mineral oil Lithium 2 Mobile, SHC 100 Chevron, Altiplex Synthetic Exxon, ronex MP Note: Temperat
Service and Maintenance 8 Tighten setscrews D and capscrews E. Figure 35: VP Type Sheave Adjustment A 9 Put on belts and adjust belt tension. Do not force belts B over grooves. See Fan Drive Belt Adjustment‚ page 30. 10 Before starting the drive, ensure that all keys are in place E and all setscrews and all capscrews are tight. Check and retighten all screws and retension belts after approximately 24 hours of service. Single Groove D Key E projects to provide a grip for removal.
Service and Maintenance MVP Variable Speed Sheaves 4 Any pitch diameter can be obtained within the sheave Mounting 1 Verify both driving and driven sheaves are in alignment and the shafts are parallel. The centerline of the driving sheave must be in line with the centerline of the driven sheave. See Figure 37. 2 Verify that all setscrews are torqued to the values shown in Table 25 before starting drive. Check setscrew torque and belt tension after 24 hours of service.
Service and Maintenance Figure 37: Sheave Adjustment Must be parallel Bearing Center lines must coincide Motor Adjustable Sheave Must be parallel Figure 38: Sheave Adjustment A d ju s ta b le C e n te r - F la n g e F ix e d C e n te r - F la n g e ( 2 ) L o c k in g S e ts c re w s "A " F la th e a d S o c k e t S c r e w s (D o N o t R e m o v e ) S p lit T a p e r B u s h in g C a p s c re w s (D o N o t R e m o v e ) McQuay IM 777-7 S ta tio n a r y E n d - F la n g e O u te r L o c k in g
Service and Maintenance Fan Drive Belt Adjustment WARNING General Rules of Tensioning 1 The ideal tension is the lowest tension at which the belt does not slip under peak load conditions. Moving belt and fan can cause severe personal injury or death. During installation and filter maintenance: • Verify that the belt and fan guards on plenum fan units are 2 Check tension frequently during the first 24 to 48 hours of always in place. operation. • Lock and tag out fans to prevent accidental start up.
Service and Maintenance Front Load Filter Option Table 27: Filter Pressure Drops Front loaded filter options require that the filters be removed and replaced from inside the unit. Efficiency 45% 65% 85% 95% Rated velocity (fpm) 625 500 500 500 Bag filters—DriPak 2000 To remove filters, rotate the wire clips. This releases both the prefilter and the final filter. When installing clean filters, check to verify the filters are fully seated in the frame (Figure 40).
Service and Maintenance Coils 1 The coil must be clean to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Use a chemical coil cleaner on multiple row coils. Read and follow the chemical cleaner’s instructions as some cleaners may contain harsh chemicals. Take care not to damage fins while cleaning. 2 Drain pans in any air conditioning unit may have some moisture. Algae, etc., can grow due to airborne spores and bacteria.
Service and Maintenance Removing the Fan Section For plenum fan assemblies, the entire fan cabinet may need to be removed to replace the entire fan assembly depending on the length of the fan section. In some cases, the fan section is not long enough for the assembly to fit out the side of the cabinet. For those cases where it will fit, follow the above steps except the neoprene seal is a D-gasket on the inlet side that needs to be removed for plenum fans.
Service and Maintenance Removing Stacked Coils Removing and Installing Staggered Coils Note: Top and bottom stacked coils are held together with steel plate and screws on one side and drain trough and screws on the other side. Remove the plate and trough before removing the coils. The coils cannot be removed attached together. Staggered coils have two banks of coils positioned a few inches apart in the direction of airflow.
Parts Replacement Parts Parts When writing to McQuay for service or replacement parts, refer to the model number and serial number of the unit stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.
Service and Warranty Procedure Warranty Service and Warranty Procedure 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.
Check, Test, and Start Procedure Form To comply with the terms of McQuay Warranty, complete and return this form within 10 days to McQuay Warranty Department. Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery. Job Name:________________________________________ McQuay S.O. No.: _________________ McQuay G.O. No.
Check, Test, and Start Procedure Form Phase L2: ___________ ___________ ____________ ____________ ___________ ___________ Phase L3 ___________ ___________ ____________ ____________ ___________ ___________ G. FLA: L1 ___________ L2 ___________ L3____________ H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control. . . . . . . . . . . . . . . . . . . . . . . . . . Yes No N/A A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality Assurance Survey Report Quality Assurance Survey Report Quality Assurance Survey Report To whom it may concern: Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the product. Job Name: _____________________________________________________ McQuay G.O. no.
McQuay Training and Development Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority. For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training, or call 540-248-9646 and ask for the Training Department. Warranty All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product Warranty. Consult your local McQuay Representative for warranty details.
