BY JOHNSON CONTROLS INSTALLATION, OPERATION & MAINTENANCE INDOOR AIR HANDLING UNIT Supersedes: ET102.19-NOM1 (1012) MODEL MQL SERIES B Form ET102.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 GENERAL SAFETY GUIDELINES IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, materials under pressure, rotating components, and both high and low voltage.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 SAFETY CONSIDERATIONS SAFETY CONSIDERATIONS WARNING Failure to follow these instructions could result in death, serious injury or equipment damage Follow all warnings and instructions in the unit's Manual(s). 1. Follow all applicable regulations and safety practices during rigging and lifting. 2. Prepare and follow written rigging and lifting plan. 3. Lifting must be directed by trained professional rigger. 4.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 CHANGEABILITY OF THIS DOCUMENT Check that the unit assembly and component weights can be safely supported by rigging and lifting equipment. All assemblies must be adequately secured during lifting and rigging by temporary supports and restraints until equipment is permanently fastened and set in its final location. Secure all dampers when servicing damper, actuator or linkages.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 TABLE OF CONTENTS TABLE OF CONTENTS GENERAL SAFETY GUIDELINES............................................................................................................................2 SAFETY SYMBOLS...................................................................................................................................................2 SAFETY CONSIDERATIONS..................................................................................................
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 TABLE OF CONTENTS TABLE OF CONTENTS (CONT’D) INSPECTION & START-UP CHECKLIST................................................................................................................17 SECTION 3 - STARTUP...........................................................................................................................................19 Electric Heat Start-Up...............................................................................................
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 LIST OF FIGURES TABLE OF CONTENTS (CONT’D) General...................................................................................................................................................30 Water Cooling Coils................................................................................................................................30 Direct Expansion Coils.................................................................................................
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 LIST OF FIGURES THIS PAGE INTENTIONALLY LEFT BLANK.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 INSPECTION SECTION 1 - INTRODUCTION Upon receipt of equipment, carefully check all items against the bill of lading to ensure that all equipment has been received. Note any discrepancy on the bill of lading before signing. Inspect all equipment for any signs of damage caused during transit. Note any visual damage on the bill of lading before signing. Immediately report all visual and concealed damage to the carrier and file a claim.
Section 1 - introduction Units with base rails can be rigged by means of lifting holes on the end of base rail (see Figure 1 on page 9). Units without base rails must be lifted with slings. Place slings at ends and joints of modules to prevent damage to equipment (see Figure 2 on page 10). Spreader bars must be used to prevent damage to equipment. Avoid twisting or uneven lifting of equipment. Do not lift equipment by coil connection or headers. See submittal drawings.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 1 - introduction b. Remove all shipped loose parts from job site to minimize theft. Tag and store parts in a safe place until needed. c. Cover entire equipment with protective tarp or moisture proof cover. Extend cover under equipment if stored on ground. Secure cover with adequate tie downs or store indoors. Be sure that all piping connections have protective shipping caps installed. d.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 1 - introduction THIS PAGE INTENTIONALLY LEFT BLANK.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 SECTION 2 - INSTALLATION 2 SIDE OF UNIT SIDE OF UNIT LD14006 Figure 6 - SUSPENDED UNITS INSTALLATION Suspending Using Factory Base Rail This equipment must be installed in strict accordance with any applicable local, state, and national codes including but not limited to building, electrical, and mechanical codes. On single wall equipment, lay rigid temporary protection, such as plywood, inside of equipment to protect insulation during installation.
Section 2 - installation FORM ET102.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 2 - installation Suspending Using Field Supplied Supports External Isolation All field supplied structural supports must be designed to support entire unit weight including all appurtenances, motor, drives, and all live or dead loads. All supports must be designed to meet applicable local codes and ordinances. Each module must be supported with an angle iron or channel.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 2 - installation DX CONNECTION STEPS In the field: TSP + 1 1. Purge the system by pressing the Schrader valve. 2. Heat the soft solder and remove the Schrader valve and flare. 3. Attach thermal expansion valve (TXV) to distributor. Notes: • DX coils are shipped capped and sealed with a Nitrogen holding charge. • Distributors are not used if only one refrigerant feeder tube provided.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 2 - installation INSPECTION & START-UP CHECKLIST A. RECEIVING & INSPECTION E. ELECTRICAL CONNECTIONS Unit Received Undamaged Refer To Unit Wiring Diagram Unit Arrangement/Hand Correct All Field Wiring In Code Compliance Unit Received Complete As Ordered Connect Incoming Power Service or Services Unit Structural Support Complete & Correct 2 F. UNIT STARTUP General Visual Unit & System Inspection B.
Section 2 - installation 18 FORM ET102.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 SECTION 3 - STARTUP ELECTRIC HEAT START-UP Rotating parts and electrical shock hazards exist. Lock out and tag out the fan motor(s) and heat power disconnects before servicing. FOLLOW THE LATEST “LOCKOUT TAGOUT” PROCEDURE. Failure to follow proper safety precautions may result in serious injury or death. All electrical connections in the heater, including both field and factory made connections, should be checked for tightness before operating the heater.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 3 - startup warranty. AC power current imbalance must not exceed 2%. Be sure that the following guidelines are met: 1. AC power is within 10% of rate voltage with frequency. (See equipment nameplate for ratings). 2. AC power is within 5% of rated frequency with voltage. 3. A combined variation in voltage and frequency of 10% (sum of absolute values) of rated values provided the frequency variation does not exceed 5% of rated frequency.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 SECTION 4 - PERIODIC MANINTENANCE AND SERVICE PERIODIC MAINTENANCE AND SERVICE General The following checklist is provided as an abbreviated guide to periodic maintenance. Detailed procedural information is given after this checklist. After 48 Hours of Operation Belts will achieve their permanent stretch and will require re-adjustment, make sure not to over-tighten. See Belts on page 27 for adjustment instructions.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service Table 1 - MINIMUM HEX HEAD BOLT TORQUE IN LB-FT - GRADE 5 BOLT SIZE (INCHES*) THREAD DESIGNATION MIN.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 3. Use a portable vacuum with HEPA filtration to remove the loose dirt and organic matter. The filter should be 99.97% efficient at .3 micron particle size. 4. If no microbial growth (mold) exists, thoroughly clean the fan and associated components with an industrial cleaning solution. Carefully follow the cleaning solution manufacturer instructions regarding use and disposal of their product. 5.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service greasing intervals. Keep the motor clean and the ventilation opening clear. The following steps should be performed at each inspection: 1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease, water, etc. This can accumulate and block motor ventilation. If the motor is not properly ventilated over heating can occur and can cause early motor failure. 2.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service Table 5 - RECOMMENDED MOTOR GREASING SCHEDULE AVERAGE DAILY OPERATING HOURS AMBIENT TEMP. MAXIMUM AVERAGE ENVIRONMENT .25 TO 7.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service BELT CENTER LINES A A SHEAVE CENTER LINES LD14010 Figure 12 - SHEAVE ALIGNMENT Mounting Split Tapper Sheaves 1. Make sure there are no nicks or burrs on the key, keyway, and shaft. If so, remove by proper methods. 2. Remove any oils, lubricants or contaminants from the bushing, capscrew, and tapered bore. 3. Check key size with both the bushing and the shaft. 4. Put bushing (B) loosely in hub of sheave (A).
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service Two groove sheaves are supplied with both grooves set at the same pitch diameter. Both movable flanges must be rotated the same number or turns to ensure the same pitch diameter for satisfactory operation. Do not open sheaves more than five turns for “a” belt or 6 turns for “b” belt. Doing so may cause the belts to sit improperly, and cause the flanges to detach in service. 1. Measuring belt span.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service 3. Gain access to the coil section of the unit. Coils 4. Use a soft brush to remove loose debris from sides of the coil. The frequency of required cleaning is dependent on the operating hours of the system, filter maintenance and efficiency as well as dirt load. 5. Use a steam-cleaning machine, starting from the top of the coil and working downward.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Refrigerant Coils Refrigerant coils should be kept clean to maintain maximum performance. If fins become dirty, clean with cold water and detergent, or one of the commercially available chemical coil cleaners. Rinse coils thoroughly after cleaning. Section 4 - periodic manintenance and service 10. Use caution to assure that any contaminated material does not contact other areas of the unit or building.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service Vibration Causes 1. Wheel imbalance. a. Dirt or debris on wheel blades. b. Loose setscrews in wheel hub or bearing-toshaft. APPLICATION RECOMMENDATION FOR COILS Observe all local codes and industry standards c. Wheel distorted from over-speed. d. Wheel balance weight missing. General 2. Bent blower shaft. 3. Drive faulty. a.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 2. DX coils are shipped capped and sealed with a 20 PSIG holding charge of dry nitrogen. Remove nitrogen charge from coil by depressing Schraeder stem, prior to cap removal. 3. Heat the soft solder and remove the Schraeder valve and flare. Section 4 - periodic manintenance and service 7. Do not attempt to lift condensate when using modulating or on/off control. 8. Size traps in accordance with manufacturers’ recommendations.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 4 - periodic manintenance and service which will be handling 35ºF, or colder, air. The desired degree of control can be obtained with a modulating valve on the downstream coil. d. Provision should always be made to thoroughly mix fresh air and return air before it enters the coil. In addition, temperature control elements must be properly located to obtain true air mixture temperatures. e.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 SECTION 5 - TROUBLESHOOTING Use Table 9 to assist in identifying the cause (s) of malfunction in the MQL. This table is intended as a diagnostic aid only. For detailed repair procedures, contact your ENVIRO-TEC ® representative.
FORM ET102.19-NOM1 ISSUE DATE:07/26/2013 Section 5 - TROUBLESHOOTING TABLE 9 - MQL TROUBLESHOOTING ANALYSIS (CONT’D) SYMPTOM EXCESSIVE MOTOR NOISE RAPID MOTOR BEARING WEAR LOOSE FAN BELT SHORT BELT LIFE BEARING NOISE LOW COIL CAPACITY (CHILLED WATER) LOW COIL CAPACITY (REFRIGERANT) DRAIN PAN IS OVERFLOWING STANDING WATER IN DRAIN PAN EXCESS DIRT IN UNIT MOLD INSIDE AIR HANDLER 34 PROBABLE CAUSE RECOMMENDED ACTION Motor mounting bolts loose. Tighten motor mounting bolts.
FORM ET102.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright © by Johnson Controls 2012 Form ET102.19-NOM1 (713) Issue Date: October 16, 2012 Supersedes: ET102.19-NOM1 (1012) 800-861-1001 www.johnsoncontrols.com Subject to change without notice.
