McQuay RAH 047C, Installation And Maintenance Manual

Page 1: ...IM 987 RoofPak Applied Rooftop Systems Air Handler Group Applied Air Systems Part Number IM 987 Date May 2009 2009 McQuay International RAH 047C 077C 12 000 to 50 000 cfm RDS 800C 802C 4000 to 20 000 cfm with MicroTech III Unit Controller ...

Page 2: ...57 Passwords 57 Navigation Mode 58 Edit Mode 58 Wiring Diagrams 59 Legend 59 Unit Options 84 Control Actuators 84 Enthalpy Control 84 External Time Clock 85 Smoke and Fire Protection 85 Smoke Detectors 85 Emergency Shutdown 86 Freeze Protection 86 Field Output Signals 87 Entering Fan Temperature Sensor 87 Duct High Pressure Limit 88 Variable Frequency Drive Operation 88 Convenience Receptacle Sect...

Page 3: ...include gas heat the nameplate is located on the lower right corner of the main control box door It includes the burner model number minimum maximum input maximum temperature rise and minimum cfm Hazard Identification Information Figure 1 Nomenclature Table 1 Program Specific Rooftop Unit Literature Rooftop unit control configuration Operation manual number VFDs McQuay 208 460 V OM 844 1 McQuay 57...

Page 4: ...s See Figure 3 page 5 for the locations of control components mounted in control panels Additional information is included in Table 2 page 12 and the wiring diagram legend which is included in Wiring Diagrams page 59 Figure 2 shows the blow through heat and the blow through coil sections Figure 2 Control Locations Economizer Filter DX Heat section Supply fan discharge plenum section C19 20 RAT LT1...

Page 5: ...s show a typical unit configuration Specific unit configurations may differ slightly from these figures depending on the particular unit options Figure 3 Control Panel Locations Main control panel Electric heat control panel optional Supply fan section VFDs line reactors and manual bypass optional Prop exhaust VFDs not shown optional ...

Page 6: ...R69 R58 GCB1 Resistor keypad Remote MCB EHB1 ERB1 VFD remote display REC1 TB1 DHL SPS1 SPS2 MMP60 MMP10 MMP20 R46 R48 HS1 S1 S7 S4 Keypad display Serial conn M60 M10 F3 M20 supply Power F1A F1B F1C T1 DS1 GND LUG DS1 TB7 blocks remaining TB2 blocks first seven TB3 detail page 14 See separate SPS1 2 fittings for static pressure tubing ...

Page 7: ...McQuay IM 987 7 Introduction Figure 5 Typical Main Control Panel Size 047C 460 Volt VFD remote display GFR1 TB7 SPS1 2 fittings for static pressure tubing TB2 F1A F1B F1C Harness Plugs ...

Page 8: ...8 McQuay IM 987 Introduction Figure 6 Typical Main Control Panel Size 077C 460 Volt Unit powered outlet and associated disconnect in seperate panel ...

Page 9: ...piCal Propeller Exhaust Panel 3 Fans 460 Volt Figure 9 VFD Bypass Panel 40 Hp 460 Volt Figure 10 Electric Heat Panel Sizes 800C 802C S3 FSG FSG Time LS1 LS2 AS IT TD10 R22 R20 R23 R21 LR10 20 M30 40 MMP30 40 M41 M42 M41 M33 M32 M31 FB33 FB32 FB31 FB43 FB42 FB41 PB3 SR2 SR3 SR1 TB11 ...

Page 10: ...e 11 Electric Heat Panel Size 047C Figure 12 Electric Heat Panel Size 077C GLG3 DS3 M41 M43 FB41 FB42 FB43 H53 TB11 M31 M32 M33 FB31 FB32 FB33 M42 GLG3 DS3 M41 M42 M43 FB41 FB42 FB43 H53 TB11 M34 M44 M31 M32 M33 FB31 FB32 FB33 FB34 FB44 ...

Page 11: ...IM 987 11 Introduction Figure 13 Harness Plug Connector Detail LT OP1 LT OP2 LT11 LT10 DFRH DFLH OPEN4 SD1 SD2 GSHT1 GSHT2 HL22 OPEN3 OAE PC7 PC5 ACT3 OPEN2 SV12 SV56 AFD10 AFD20 FP1 OPEN1 EPTS RATS OATS DATS ...

Page 12: ...as required A D Temperature 3 5 F 2 C Humidity 5 fixed 030706702 Enthalpy control electronic Returns outside air dampers to minimum position when outside air enthalpy is higher than return air empalthy use RAE Auto Economizer section Fully CW past D when used with RAE A D N A 049262201 OAT Outside air temperature sensor Senses outside air temperature N A N A N A 060004705 PC5 Dirty filter switch S...

Page 13: ...e pressure Converts static pressure signals to voltage signals N A Main control box N A 025 0 25 wc 62 3 62 3 Pa 1 5 V dc out N A 049545006 S1 System switch Shuts off entire control circuit except crankcase heaters N A Main control box N A N A N A 001355000 S7 ON OFF AUTO switch Used to manually switch unit N A Main control box N A N A N A Table 2 Controls Settings and Functions continued Symbol D...

Page 14: ...make sure the voltage complies with the power supply available Unit Clearances Service Clearance Allow an approximate service clearance as indicated in Figure 14 Also McQuay recommends providing a roof walkway to the rooftop unit as well as along two sides of the unit that provide access to most controls and serviceable components Figure 14 Service Clearances Unit with Housed DWDI Supply Fan CAUTI...

Page 15: ...dy conditions are common install wind screens around the unit maintaining the clearances specified see Figure 16 This is particularly important to prevent blowing snow from entering the outside air intake and to maintain adequate head pressure control when mechanical cooling is required at low outdoor air temperatures Overhead Clearance 1 Unit s surrounded by screens or solid walls must have no ov...

Page 16: ...d Obstruction 24 610 mm Maximum Overhead Canopy 9 229 mm Minumum to Flue Box Typical All Sides Flue Box Side Discharge Opening Access in Ductwork Must be Removed NOTICE On units with side discharge access to plenum mounted components becomes difficult once ductwork is installed Installer must provide access in the ductwork for plenum mounted controls ...

Page 17: ...rb length Assembly instructions 1 Set curbing parts A through H per dimensions shown over roof opening or on a level surface see Figure 18 page 18 Note location of return and supply air openings 2 If applicable set other curbing parts D L M etc in place making sure that the orientation complies with the assembly instructions see Detail A Check alignment of all mating bolt holes 3 Bolt curbing part...

Page 18: ...Using remaining side supports in this area align lengths on opposite sides of assembly and install a cross support D at each side D M L M Detail A RAH unit Dimensions X Y in mm in mm 047C 38 965 28 711 077C with flat cooling coil and or 44 SWSI plenum supply fan 62 157 5 38 965 077C with staggered or no cooling coil and or 49 SWSI plenum supply fan 62 157 5 46 1168 Main unit curb Unit base Curb ga...

Page 19: ... 0 610 82 0 2083 6 8 173 1 5 38 2 15 FC 24 0 610 82 0 2083 6 8 173 1 5 38 2 15 FC 24 0 610 82 0 2083 6 8 173 1 5 38 30 AF 30 0 762 76 0 1930 6 8 173 4 5 114 30 AF 30 0 762 76 0 1930 6 8 173 4 5 114 40 AF 36 0 914 78 0 1981 14 8 376 3 5 89 40 AF 36 0 914 78 0 1981 14 8 376 3 5 89 D Return Air F B F E X Inside Y Inside 85 00 2159 mm 62 80 1594 mm A B E YY XX D See Detail A 38 80 984 mm C G G C H H A...

Page 20: ...rigging instructions for both roof curb and post and rail arrangements Roof Curb Arrangement 1 Set the rooftop unit on the roof curb McQuay Rooftop units are designed to overhang from the roof curb 2 Adjust the seismic hold down brackets so they come into contact with the unit base per Figure 22 and Figure 23 page 21 a The seismic hold down brackets should be adjustable and accommodate the overhan...

Page 21: ...er wiring by factory Unit control wiring by factory High temp Insulation Roof curb Acceptable weld zone Field attachment weld Weld zone 25 50 Unit base Seismic hold down bracket Unit power wiring by factory Unit control wiring by factory Roof curb Shim spacer It may be necessary for the contractor to field fabricate spacers or new seismic hold downs for rooftop units having larger overhang dimensi...

Page 22: ...e insulation is installed at the factory to allow for field welding along the lower front edge region of the unit base Figure 24 Welding of Unit To Rail Unit Base Cross Sectional View Figure 25 Weld Locations for Rail Arrangement CAUTION When welding unit to the curb do not damage wiring control panel side Weld ONLY in the specified zone in the acceptable weld zone see Figure 24 Welding must compl...

Page 23: ...nce Curb View RDS 800C 802C Shown For Exact Values Refer to Submittal Unit length minus 6 4 12 1 See Detail A Detail A 3 4 5 1 0 9 Dia K O 3 0 Dia K O 4 6 4 8 2 0 2 1 4 3 3 1 9 7 E 8 0 97 0 76 0 6 0 7 5 20 0 1 5 6 0 6 8 R A OPNG B 2 Typ A A D C D 4 Typ A B B S A OPNG RPS only ...

Page 24: ...e 3 Provide proper drainage around the unit to prevent flooding of the equipment 4 Provide adequate protection from vandalism mechanical contact etc 5 Securely close the doors 6 If there are isolation dampers make sure they are properly installed and fully closed to prevent the entry of animals and debris through the supply and return air openings 7 Cover the supply and return air openings on unit...

Page 25: ...on length refer to Figure 29 and Table 5 for this dimension If A 288 7315 mm 4 point lifting is sufficient If A 288 7315 mm 6 point lifting is required Figure 29 Unit Type RAH Lifting Points Table 4 RAH X Dimension See Figure 29 Economizer Section Type of economizer section 047C 077C 100 OA 0 0 Plenum 48 1219 mm 72 1829 mm 0 30 OA 48 1219 mm 72 1829 mm 0 100 economizer 72 1829 mm 96 2438 mm 0 100 ...

Page 26: ... takes place in three phases 1 setting the sections 2 mechanically recoupling the cabinet and 3 reconnecting power and control wiring Phase I Set sections 1 Remove top cap and save for Phase II Step 1 2 Remove screws on fan panel leaving retainer clips in place to secure bulkhead Save screws for Phase II Step 5 3 Remove plywood and retaining angles from unit and discard 4 Carefully lower both sect...

Page 27: ...aulk 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 See detail Splice cover provided 10 screws provided Nut clip on provided Caulk vertical seam Install screws 25 to 20 75 saved from step 1 ...

Page 28: ...ed refrigerant piping may exit the unit cabinet at one of the following locations Through the floor of the unit Through the discharge and bulkhead of the unit Through a cabinet door near the DX coil that is not required for service areas In preparing for field piping remove the plastic plugs on the distributors and unsweat the copper caps at the suction header connections Follow piping design sizi...

Page 29: ...lectronic leak detector After making any necessary repair the system should be evacuated as described in the following paragraphs Evacuation After determining the unit is tight and there are no refrigerant leaks evacuate the system 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 1 Connect a mercur...

Page 30: ...stand the drum with the connection side up and place the service valve in the open position Important At this point interrupt the charging procedure and do prestart checks before attempting to complete the refrigerant charge Note Stamp the total operating charge per circuit on the unit nameplate for future reference Take special care to add refrigerant slowly enough to the suction to prevent damag...

Page 31: ...netrate the roof external to the unit Refer to local codes for additional requirements Sealed drain lines require venting to provide proper condensate flow Where the cooling coils have intermediate condensate pans on the face of the evaporator coil copper tubes near both ends of the coil provide drainage to the main drain pan Check that the copper tubes are in place and open before the unit is put...

Page 32: ...T size as the valve male threads at the supply connection female threads at the return connection 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 Glycol solutions or brines are the only freeze safe media for operation of water coils at low entering air temperature conditions Re...

Page 33: ...on power failure This allows full flow through the coil Figure 36 Two Way Valve Package Steam Piping Recommendations 1 Be certain that adequate piping flexibility is provided Stresses resulting from expansion of closely coupled piping and coil arrangement can cause serious damage 2 Do not reduce pipe size at the coil return connection Carry return connection size through the dirt pocket making the...

Page 34: ...ping with Vestibule Steam Coil Freeze Conditions If the air entering the steam coil is below 35 F 2 C note the following recommendations 1 Supply 5 psi 34 5 kPa steam to coils at all times 2 Modulating valves are not recommended Control should be by means of face and bypass dampers 3 As additional protection against freeze up install the tap sufficiently far below the coil to provide an adequate h...

Page 35: ...eat connection information for units not furnished with factory installed piping and valve packages With the factory piping and valve package the coil assembly is controlled through a single three way valve When two coils are included in the assembly they are piped in parallel Field connections are male NPT sized as shown in Table 10 Refer to Figure 40 for a typical cooling coil with factory valve...

Page 36: ... S A S 4 F U E T C S C S C S 5 F U E T C S A S 6 F U E T C S C S A S 8 F U E T C S C S C S Face and bypass section with large coil 39 39 2 coils 991 991 mm 45 0 4 18 m 3 D R C Q A Q A P 4 D R C Q C Q C Q B P 5 D R C Q C Q A P 6 D R C Q C Q C Q A P 8 D R C Q C Q C Q B P 077C Blow thru or draw thru small coil section 45 45 2 coils 1143 1143 mm 51 9 4 82 m 3 C R C Q A P A P 4 C R C Q C P B P B P 5 C ...

Page 37: ...ght is 21 30 inches and 2 50 inches of fin height is 30 36 inches L A single 1 50 inch NPT supply and return M A single 2 00 inch NPT supply and return if fin height is 21 30 inches N A single 2 50 inch NPT supply and return P Two 3 12 inch O D supply and two 3 12 O D return connections Q Two 2 62 inch O D supply and two 2 62 O D return connections R Two 2 12 inch O D supply and two 2 12 O D retur...

Page 38: ... the vestibule Step 1 Remove door from section where vestibule is to be located by removing screws holding hinges to upright support leave hinges on door Set door aside and save for Step 4 Remove door latch assembly from other side upright support Use offset Phillips screwdriver or a wrench to remove screws holding latch assembly in place Save door latch assembly screws and bushings for Step 4 Fig...

Page 39: ...d from Step 1 Access door must be attached to the vestibule in the same opening direction as it was on the unit 2 Remove and discard latch handle locking screws and retaining washer Fasten door latch assembly to side panel using screws and bushings saved from Step 1 Latch must be fastened on the same side as when located on the unit 3 Fasten upright angles to vestibule using 10 screws supplied 4 S...

Page 40: ...through a 90 degree angle to bring the economizer dampers from full open to full close see Figure 45 Access to the actuator and linkage is from the filler section Mechanical stops are placed in the crankarm mounting bracket Do not remove stops Driving the crankarm past the stops results in damage to the linkage or damper The unit ships with a shipping bolt securing the linkage crankarm Remove ship...

Page 41: ... 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 During unit operation the two position actuator drives the damper to the position set on the keypad During the off cycle the damper is automatically closed No unit mounted exhaust da...

Page 42: ...ield installed controller automatic operation can be obtained These dampers provide a similar function to economizer dampers This option differs from an economizer in that no unit mounted exhaust dampers are provided Note For good airflow control adjust linkages so damper blades do not open beyond 70 degrees Opening a damper blade beyond 70 degrees has little effect on its airflow Do not over clos...

Page 43: ...ce 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 800C 802C Only Figure 50 Face and Bypass Dampers Staggered Arrangement RAH 047C 077C Only Airflow 75 19mm 90 Stroke Face Dampers Open Face Dampers Closed 3 00 76mm Face and Bypass Damper 75 19mm Open Closed 25 6mm 90 Stroke 3 00 ...

Page 44: ...ge 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 Extended Shaft Face and Bypass Damper Optional Contractor Coil Face and Bypass Dampers CAUTION Transportation rigging or maintenance can damage the unit s weather se...

Page 45: ...ize losses and sound transmission design duct work per ASHRAE and SMACNA recommendations Where return air ducts are not required connect a sound absorbing T or L section to the unit return to reduce noise transmission to the occupied space Ductwork exposed to outdoor conditions must be built in accordance with ASHRAE and SMACNA recommendations and local building codes Figure 52 Installing Duct Wor...

Page 46: ...tap in a nonturbulent flow area of the duct Keep it several duct diameters away from take off points bends neckdowns attenuators vanes or other irregularities 5 Use a static pressure tip Dwyer A302 or equivalent or the bare end of the plastic tubing for the duct tap If the duct is lined inside use a static pressure tip device 6 Install the duct tap so that it senses only static pressure not veloci...

Page 47: ...tap to the sensor results in unsatisfactory operation 6 Use an outdoor static pressure tip Dwyer A306 or equivalent to minimize the adverse effects of wind Place some type of screen over the sensor to keep out insects Loosely packed cotton works well 7 Route the outdoor tap tube out of the main control panel through a small field cut opening in the edge of the control wiring raceway cover see Figu...

Page 48: ...switch is not fused Power leads must be over current protected at the point of distribution The maximum rated overcurrent protection device MROPD appears on the unit nameplate All RDS and RAH Units All units are provided with internal power wiring for single or dual point power connection The power block or an optional disconnect switch is located within the main control panel Field power leads ar...

Page 49: ...wer Wire Entrance Unit View RDS 800C Shown Actual Opening Shown on Submittal Documents R e m o v e L i f t i n g B r a c k e t I f L o c a t e d H e r e B e f o r e D r i l l i n g H o l e M a i n C o n t r o l P a n e l 2 7 5 7 0 m m 3 7 6 m m M a x D i a 1 6 4 0 6 m m CAUTION Wires are located in base rail Move wires before drilling hole through base rail Detail B 12 0 8 8 3 8 0 9 Dia K O Qty 4 ...

Page 50: ... main control panel near the power wire entry point Note All wire sizes assume separate conduit for each set of parallel conductors Note All wire sizes based on NEC Table 310 16 for 75 C THW wire copper Canadian electrical code wire ampacities may vary Note All wire sizes assume no voltage drop for short power leads CAUTION Provide proper line voltage and phase balance Improper line voltage or exc...

Page 51: ...nd Control Panel page 5 Two 7 8 knockouts are provided for wire entry Figure 59 Field Control Wiring Connections Interconnecting wiring enters the air handler unit through 7 8 knockouts in the bottom of the main control panel The interconnecting wiring is connected to TB4 in the air handler unit Refer to Figure 60 A 7 8 knockout is also available in the end of the unit base as shown in Figure 59 N...

Page 52: ...lightly compress the spring or raise the sled to allow the bolt to turn freely Place one or two drops of oil on the threads if needed Use a wide flat blade socket drive bit with a recommended 1 2 drive handle Ensure that as the slotted bolt is turned the upper rebound plate also turns This action allows the bolt to compress decompress the compression plate while having the same affect on the sprin...

Page 53: ...ounted on springs After the spring mounts are adjusted for level operation when the fan is running check the thrust restraints With the fan off set the adjustment nuts so the spring is slightly compressed against the angle bolted to the fan housing frame Refer to Figure 66 When the fan is turned on the fan moves back to a level position and the thrust restraint spring compresses Figure 66 Thrust R...

Page 54: ...ed fan assembly to 0 25 6 mm in any direction thereby helping to prevent the fan from being tossed about and damaged or causing damage When a seismic restraint is properly adjusted and the fan is operating normally the neoprene center bumper is centered within the 2 51 mm diameter hole in the restrainer angle and the restrainer angle is centered vertically between the flanges of the neoprene cente...

Page 55: ...ol fan operation Note Unit ships with factory installed jumpers between TB2 101 and 105 and between 101 and 106 Fan 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 not shown After the 3 minute timer expires the uni...

Page 56: ...g input AIX5 drives the outdoor air dampers toward the open and closed line 256 position If the outdoor air dampers are wide open and more cooling is required the dampers hold their positions and mechanical cooling is activated see below When the outdoor air is not suitable for free cooling the switch in enthalpy sensor OAE is in position 1 de energizing analog input AIX5 Alternatively the outdoor...

Page 57: ...ems that are applicable to the specific unit configuration are displayed The Alarm Lists Menu includes active alarm and alarm log information The System Summary Menu includes status information indicating the current operating condition of the unit Standard Menus include basic menus and items required to setup the unit for general operation These include such things are control mode occupancy mode...

Page 58: ...the next line down on the page When the wheel is turned counter clockwise the cursor moves to the previous line up on the page The faster the wheel is turned the faster the cursor moves When the Back Button is pressed the display reverts back to the previously displayed page If the Back button is repeated pressed the display continues to revert one page back along the current navigation path until...

Page 59: ...ol circuit transform er T1 primary Main control box F1C Fuse control circuit transform er T1 secondary Main control box F2 Fuse control circuit transform er T2 primary Main control box F3 Fuse burner blower motor Main control box FB31 40 Fuseblock electric heat top bank Electric heat box FB41 50 Fuseblock electric heat bot bank Electric heat box FD Flame detector Heat section gas FLC Fan limit con...

Page 60: ...ol box R46 47 Relay supply fan inverter incr decr Main control box ID Description Standard location R48 49 Relay return fan inverter incr decr Main control box R58 59 Relay heat wheel inverter incr decr Main control box R60 Relay energy recovery wheel enable Main control box R61 Relay smoke detector dis charge air Main control box R62 63 65 Relay use on specials Main control box R66 Relay smoke de...

Page 61: ...on VM5 Valve motor 5 cooling Coil section cool VV1 Vent valve gas heat Heat Section Gas ZNT1 Zone temp sensor setback Field installed ID Description Standard location 200 H200 1 Field wiring 3 Shielded wire cable 4 Main control box terminals 5 Auxilliary box terminals 6 Field terminals 7 Plug connector 8 Wire harness number General Notes 2 Factory wiring 9 Wire nut ID WN7 ...

Page 62: ... Power ELECTRICAL CIRCUIT 1 CUSTOMER SUPPLIED POWER 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 G T3B T2B T1B T3A T2A T1A L3 L2 L1 GLG1 DS1 Schematic continues on next page ...

Page 63: ...170 426 426 431 426 108 108 108 MTR MTR T3 T2 T1 T3B T3A T2B T2A T1B T1A L3B L3A L2B L2A L1B L1A T3 T2 L3 L2 T1 L1 T3 T2 T1 T3 T2 L3 L2 T1 L1 T3B T3A T2B T2A T1B T1A L3B L3A L2B L2A L1B L1A 1 2 3 4 5 6 7 8 GRD 2 1 2 1 2 1 X3 X1 X2 H4 H3 H2 H1 T3 1 T2 1 T1 1 T3 3 T2 3 T1 3 T3 5 T2 5 T1 5 SUPPLY FAN NB MMP10 M10 RETURN FAN NB M20 MMP20 TB1A TB1A F1C F1A F1B T1_N T1 T1_115VAC DS1 DS1 DS1 168A 168C 16...

Page 64: ...18 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 219 426 221 256 115V 24V CLASS 2 ECON OADM 3 2 4 1 14 15 GRD 16 2 1 10 11 12 13 23 24 55 3 1 114 54 5 4 2 H 115 6 17 16 8 6 2 1 2 CW 4 R COM WHT 1 CCW BLK 7 67 68 69 H G N G H N 10 2 1 3 2 1 56 113 53 H 115 6 17 16 6 5 2 3 1 T2 TB1B T1_115VAC T1_N S1 TB1B TB1D T2_115VAC TB2 P20 PP TB2 TB2 P20 PP ...

Page 65: ...ACT NOTE THESE CONTACT ARE FOR USE IN A 24 VOLT A C CLASS 2 CIRCUIT DUCT HI LIMIT 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 426 219 14 13 104 108 7 6 105 106 M10 TB2 TB2 R63 TB2 TB2 26OA 260B 256A 256B Schematic continues on previous page ...

Page 66: ...66 McQuay IM 987 Wiring Diagrams Figure 74 VAV Fan Power with SAF and RAF VFDs and Manual Bypass Schematic continues on the next page ...

Page 67: ...McQuay IM 987 67 Wiring Diagrams Figure 75 VAV Fan Power with SAF and RAF VFDs and Manual Bypass Continued Schematic continues on the previous page ...

Page 68: ...D POWER 106 107 108 109 110 111 112 113 133 134 135 136 137 138 139 140 141 426 109 426 MTR T3 T2 T1 T3B T3A T2B T2A T1B T1A L3B L3A L2B L2A L1B L1A T3 T2 L3 L2 T1 L1 G T3 T2 T1 L3 L2 L1 L3B L3A L2B L2A L1B L1A L3 3 L2 3 L1 3 SUPPLY FAN MMP10 M10 GLG1 DS1 PB11 PB11 111A 110A 109A 137A 138A 139A 137 138 139 Schematic continues on next page ...

Page 69: ...52 161 162 163 164 165 166 167 168 169 170 109 431 109 426 MTR 2 1 2 1 2 1 X3 X1 X2 H4 H3 H2 H1 1 2 3 4 5 6 7 8 GRD L3 1 L2 1 L1 1 T3 T2 T1 T3 T2 L3 L2 T1 L1 T3B T3A T2B T2A T1B T1A L3B L3A L2B L2A L1B L1A L3 6 L2 6 L1 6 F1C F1A F1B T1_N T1 T1_115VAC TB1A TB1A PB11 RETURN FAN M20 MMP20 PB11 168A 168C 168B 164A 162A 164 162 149 150 151 Schematic continues on the previous page ...

Page 70: ...70 McQuay IM 987 Wiring Diagrams Figure 78 VAV Control Inputs Schematic continues on next page ...

Page 71: ...McQuay IM 987 71 Wiring Diagrams Figure 79 VAV Control Inputs Continued Schematic continues on previous page ...

Page 72: ...8 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 207 207 207 364 362 207 207 239 SRC FAN_OPERATION EXT_ALARM_SIGNAL BO4 BO3 24V SRC jprs 24V SRC jprs 115V 24V CLASS 2 24V SRC jprs OPEN BO6 24V SRC jprs ECON ACT CLOSE BO5 1 8 10 2 18 19 20 21 4NO 4 3NO 3 117 115 116 3 2 4 1 8 6 7 2 1 6NO 6 3 CCW X COM L2 2 CW L1 5NO 5 R26 T1_N T2_115VAC TB1C ...

Page 73: ...64 365 366 367 368 369 306 306 207 207 243 RECTIFIER DC 12V 115V RELIEF DAMPER OPP DR SIDE RELIEF DAMPER DRIVE SIDE HEAT OPEN B10 CLOSE B09 24V SRC jprs 24V SRC jprs AC AC L1 X1 L2 X2 1 3 BLK WHT WHT BLK 8 9 11 33 36 35 34 5 7 6 5 5 5 5 5 5 5 6 6 6 6 6 6 6 5 8 7 9 6 L2 X COM L1 3 CCW 2 CW 10NO 10 9NO 9 RECT T4 PL17 PP ACT11 NB ACT10 NB R26 TB1F TB1F TB1F TB1F R26 PL18 PP PL18 PP PL18 PP PL18 PP PL...

Page 74: ...74 McQuay IM 987 Wiring Diagrams Figure 82 VFD Control SAF and RAF Schematic continues on next page ...

Page 75: ...McQuay IM 987 75 Wiring Diagrams Figure 83 VFD Control SAF and RAF Continued Schematic continues on previous page ...

Page 76: ...RC jprs 24V SRC jprs 6000V X1 X2 115V FSG G FSG F FLAME ROD FD MICROCOMPUTER 5K1 2K1 1K1 L1 6K1 3K1 4K1 2K2 FLAME AMPLI FIER T I M E R FSG FLAME SAFEGUARD PLUG IN TYPE CONTROLLER BLK BLK 10NO 10 8 9 9 11 12 9NO 9 2 1 R BLK WHT 6 5 4 6 5 4 5 6 4 RED_G630 B WHT_G630 W YEL_G632 R YEL_G633 1 YEL_G634 2 3 1 NO COM 4 2 2 1 3 1 COM NO NO COM 3 1 C2 C1 C2 C1 20 20 20 20 20 20 20 WHT BLK WHT BLK WHT BLK WH...

Page 77: ...OR BO 10 ON THE MAIN CONTROL BOARD MCB ARE CLOSED THE ACTUATOR WILL REMAIN WILL RE POSITION TOWARD A HIGHER FIRING RATE UNTIL BO 10 OPENS OR THE ACTUATOR REACHES ITS MAXIMUM POSITION WHEN THE MAIN CONTROL SYSTEM CLOSES BO 9 THE BURNER AIR AND GAS VALVES FOR THE REQUIRED FIRING RATE WHEN THE MAIN CONTROL SYSTEM CLOSES BO 10 ON THE MAIN CTRL BRD MCB THE GAS VALVE ACTUATOR AFTER THE FLAME HAS LIT AND...

Page 78: ...FLAME AMPLI FIER T I M E R FSG FLAME SAFEGUARD PLUG IN TYPE CONTROLLER 6000V X1 X2 115V BLK BLK 9 9 8 10NO 10 9NO 9 5 6 4 11 12 RED_G630 B WHT_G630 W YEL_G632 R YEL_G633 1 YEL_G634 2 2 1 R WHT BLK C2 C1 COM NO 21 21 21 21 21 21 21 BLK BLK BLK WHT BLK WHT 10 7 6 9 8 L2 3 4 5 L2 L1 2 6 3 5 4 NB RED_G617 L 20 20 20 20 20 20 20 WHT_G617 R 8 7 1 L4 L3 L2 L1 5 3 1 11 4 8 2 10 5 7 1 3 8 7 1 2 2 1 4 2 8 9...

Page 79: ...ALL FOR HEAT THE CONTROL SYSTEM WILL CLOSE BO 11 ON THE MAIN CTRL BRD MCB THUS ENERGIZING RELAY R20 WHEN THE ROOFTOP UNIT IS ENERGIZED 120 VOLT POWER IS SUPPLIED TO THE SYSTEM ON OFF SWITCH S1 TO BURNER ON OFF SWITCH S3 AND 24 VOLTS TO THE BO 11 POWER IS FURNISHED THROUGH THE SYSTEM ON OFF SWITCH S1 THROUGH THE BURNER ON OFF SWITCH S3 THROUGH RELAY R20 CONTACTS THROUGH THE HIGH LIMIT CONTACTS ON T...

Page 80: ... T3 T2 T1 L3 L2 L1 L3 L2 L1 T3 T2 T1 4 3 2 1 T3 T2 T1 L3 L2 L1 L3 L2 L1 T3 T2 T1 L3 8 L2 8 L1 8 L3 3 L2 3 L1 3 T3 T2 T1 L3 L2 L1 L3 L2 L1 T3 T2 T1 L3 4 L2 4 L1 4 T3 T2 T1 L3 L2 L1 L3 L2 L1 T3 T2 T1 4 3 2 1 4 3 2 1 L3 L2 L1 PB3 PB3 M31 FB31 HTR1A HTR3A HTR3B M43 FB43 PB3 HL12 HTR2B M42 FB42 PB3 HL11 HTR1B M41 FB41 PB3 HL4 HTR4A HL3 HL2 HTR2A PB3 M32 FB32 HL1 M44 FB44 PB3 PB3 M33 FB33 PB3 M34 FB34 H...

Page 81: ...A 554B 553A 552A 552B 552C 550A 550B 550C 549A 548A 548B 547A 546A 546B 546C 544B 538A 538B 536A 536B Schematic continues on previous page HEATER BANK A M31 1 A M32 2 A M33 3 A 120 KW HEATER BANK B M41 1 B M34 4 A 5 A 6 A M44 4 B M43 3 B M42 2 B 8 B 7 B 120 KW 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568...

Page 82: ... RETURN FAN ON OFF 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 149 137 137 260 149 219 A1 A2 A1 A2 76 75 76 75 208 209 207 8 11 M10 M20 MMP20 MMP10 T1_N 115VAC_GF 1 TB4 TB4 TB4 R63 431A 426A 426B 426C 426D ...

Page 83: ...7 jprs 24V SRC MCB 1 1NO BO1 SUPPLY FAN 207 SRC 9 16 MCB 207 11 31 MMP10 12 32 11 31 MMP20 12 32 TO MOTHERBOARD WIRED INTERNAL SOURCE 9 16 T3_COM 3 11 T3_24V 3 11 115VAC_GF 1 T1_N 1 68 1003B 1003A 1004B 1005B 1005A N TB7 G TB7 H TB7 REC1 CP SL GRD SL CP PL32 1 S11 PL31 1 S10 G1004 2 PL32 G1012 N G REC11 H 31 LT11 BLK WHT w 2 PL31 G1009 N G REC10 H 30 LT10 BLK WHT w FIELD SUPPLIED 115V 60 1 H1010 2...

Page 84: ...e control points at 50 RH for settings A through D Figure 94 shows this scale on a psychrometric chart When the outside air conditions exceed the setting of the device the outside air dampers are positioned to the minimum outside air intake position by the MicroTech III controller Figure 94 Enthalpy Control Settings REC1 FIELD SUPPLIED 115V 60 1 Table 14 Enthalpy Control Settings Control curve Con...

Page 85: ...al Time Clock You can use an external time clock as an alternative to or in addition to the MicroTech III controller s internal scheduling function The external timing mechanism is set up to open and close the circuit between field terminals 101 and 102 When the circuit is open power is not supplied to binary input MCB BI1 This is the normal condition where the controller follows the programmable ...

Page 86: ...controller begins checking the freezestat again If the freezestat is open the heating valve closes If the freezestat closes again the heating valve opens and the 10 minute timer resets The unit remains shut down until the Freeze Fail alarm is manually cleared Refer to the operation manual supplied with the unit for information on clearing alarms OM138 or OM137 Fan Off Operation If the freezestat d...

Page 87: ...es are driven to their Heating Position when hot air is provided based on either the normally open or normally closed contacts of the VAV output The VFD will continue to be controlled to maintain the desired duct static pressure This output is also off when the unit is in the Startup or Recirculation states If this output is in the Heat off position when the unit enters the Fan Only state or Minim...

Page 88: ...n the field so that the DesignFlow unit is in the same orientation as when it was factory calibrated See DesignFlow Station Startup below The rotational position of the DesignFlow unit vane is translated into CFM by the microprocessor in the MicroTech III control system The position of the vane is determined by two things the force of the airflow impacting the vane and the gravitational effect on ...

Page 89: ...that the duct tape will stick to it b Pre apply duct tape to the top surface of the bottom portion of the fulcrum extending it about one inch beyond the edges on three sides c With the alignment plate taped to the vane and the vane in the zero airflow position locate the fulcrum parallel to and against the alignment plate Note The zero airflow position is when the vane is swung away from the back ...

Page 90: ...ithin the specified range carry out the following steps 1 Unlock and open the louvered outdoor air intake door on the side of the unit 2 Loosen the two 1 4 20 NC lock nuts at the top of the DesignFlow frame see Figure 101 Figure 101 DesignFlow Frame 3 Close and lock the intake door 4 Remove the cover from the access opening in the bottom blade of the outdoor air intake louver see Figure 102 5 Loos...

Page 91: ...covered in other sections of this manual Figure 104 Two Fans with Back Return Prestarting Checks Check all fasteners and set screws for tightness This is especially important for bearing set screws The propeller should rotate freely and not rub on the fan panel venturi Rotation direction of the propeller should be checked by momentarily turning the unit on Rotation should be in the same direction ...

Page 92: ... On some fans fasteners attaching the motor to the motor plate must be loosened to adjust the belt It is very important that the drive pulleys remain in proper alignment after adjustments are made see Figure 107 Misalignment of pulleys results in premature belt wear noise vibration and power loss Figure 106 Belt Adjustment Figure 107 Drive Pulley Alignment Figure 108 Propeller Exhaust Fan Replacem...

Page 93: ...ly clean the exterior surface of the motor fan panel and entire propeller periodically Dirt can clog cooling openings on motor housings contaminate bearing lubricant and collect on propeller blades causing severe imbalance if left unchecked Use caution and do not allow water or solvents to enter the motor or bearings Under no circumstances should motors or bearings be sprayed with steam or water E...

Page 94: ...UV lamps when opened These switches are designed to prevent UV exposure when cabinet doors are opened and must not be disabled A viewing window near the UV lights allows viewing to determine if the lights are energized The viewing windows use specially designed glass that blocks harmful UV light Figure 109 Typical Ultraviolet Light Installation WARNING UVC exposure is harmful to the skin and eyes ...

Page 95: ...l 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 24 V ac to the coil of relay R45 When all doors are closed relay R45 is energized and its normally open contacts in series with system switch S1 provide 115 V ac to the UV ligh...

Page 96: ...y that the evaporator condensate drain is trapped and that the drain pan is level 13 If unit is curb mounted verify that the curb is properly flashed to prevent water leakage 14 Before attempting to operate the unit review the control layout description to become familiar with the control locations 15 Review the equipment and service literature the sequences of operation and the wiring diagrams to...

Page 97: ...lgorithm should start to modulate the dampers open to maintain the discharge air setpoint e If the outdoor enthalpy is high the dampers should maintain their minimum position Look at menu Temperature OA Damper MinOA Pos Change this entry to another value Verify that the dampers move to the new minimum position setpoint 5 If the unit is equipped with the electromechanical enthalpy changeover contro...

Page 98: ...he coil when the valve stem is down If the unit loses power the spring in the actuator should drive the valve wide open to the coil Check this by opening system switch S1 Air Balancing 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...

Page 99: ...nsioning shortens belt and bearing life 4 Keep belts free from foreign material which may cause slippage 5 Make V drive inspection on a periodic basis Adjust tension if the belt is slipping Do not apply belt dressing This may damage the belt and cause early failure Tension Measurement Procedure 1 Measure the belt span See Figure 112 2 Place belt tension checker squarely on one belt at the center o...

Page 100: ...d 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 tight before starting the drive Check the setscrews and belt tension after 24 hours of service Figure 113 VM and VP Variable Pitch Sheaves LVP Variable Pitch Sheaves Mounting 1 For single groove sheaves slide ...

Page 101: ...e motor toward the driven shaft until the belts are free from the grooves For easiest adjustment remove the belts 2 Loosen both locking screws A in outer locking ring but do 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 ...

Page 102: ...t i o n A A A B C D E F D E A E C F D A A C e n t e r F l a n g e s G a p O u t e r L o c k i n g R i n g L o c k i n g S c r e w s A 3 C a p s c r e w s B I n n e r L o c k i n g R i n g S p a n n e r W r e n c h H o l e 2 L o c k i n g S c r e w s A E n d F l a n g e C e n t e r F l a n g e A s s e m b l y T h r e a d B a r r e l B a r r e l F l a n g e 1 8 S h o r t K e y H e r e L o n g K e y ...

Page 103: ... using the keypad menu Setup Service Unit Configuration Calibrate Mode and changing the value from NO to YES The calibrate mode automatically zeroes all static pressure sensors and calibrates any actuator feedback pots connected to the MicroTech III controller When the calibration is finished the keypad menu System Summary System Unit Status changes from Calib to Off Man 15 To restart the unit rec...

Page 104: ...104 McQuay IM 987 Final Control Settings Figure 117 Keypad Accessible Menu Structure ...

Page 105: ...McQuay IM 987 105 Final Control Settings Figure 118 Keypad Accessible Menu Structure Continued ...

Page 106: ... door latch mechanisms Unit Storage Location The McQuay Rooftop Airhandling Unit is an outdoor unit However the schedule may dictate storage either on the ground or in its final position at the site If the unit is stored on the ground additional precautions should be taken as follows Make sure that the unit is well supported along the length of the base rail Make sure that the unit is level no twi...

Page 107: ...d other issues that may have developed during the storage interval Gas Furnace For information on maintenance of the gas furnace refer to Bulletin No IM 684 or IM 685 Bearing Lubrication Motor Bearings Supply and return fans Supply and return fan motors should have grease added after every 2000 hours of operation Using the following procedure relubricate the bearings while the motor is warm but no...

Page 108: ...p bearing and add the second half of the recommended amount A temperature rise sometimes 30 F 19 C after relubrication is normal Bearing should operate at temperature less than 200 F 94 C and should not exceed 225 F 107 C for intermittent operation For a relubrication schedule see Table 17 For any applications that are not in the ranges of the table contact McQuay CAUTION The tables below state ge...

Page 109: ...ths Setscrews 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 Refer to Table 23 and check the tightness of all setscrews with a torque wrench Note that if the return fan bearings setscrews must be retightened a special procedure is ...

Page 110: ...heel to Funnel Figure 121 24 DWDI backward curved wheel to funnel 036C 040C Figure 122 27 to 40 DWDI Airfoil Wheel to Funnel Alignment Figure 123 40 SWSI Airfoil Wheel to Funnel Alignment Figure 124 44 and 49 SWSI Airfoil Wheel to Funnel Alignment Experience in the field has shown that R 407C systems can be topped off after a leak has been repaired and operate normally There is no need except in t...

Page 111: ...each MMP as a means to differentiate between a short circuit and overload trip conditions The MMP trip points are factory set Do not change unless the motor ampacity changes or the MMP is replaced with a new 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...

Page 112: ...onnections resist failure due to vibration Easily identifiable terminal markers Combination spring release and square test ports To insert a wire to the terminal connector 1 Insert a small flat blade screwdriver into the square hole 1 in Figure 127 adjacent to the desired wire location 2 in Figure 127 to open the spring clamp 2 Strip approximately 1 2 of insulation from the wire 3 Insert the strip...

Page 113: ...disable power 1 Recommended method to access the controls through the release method defeats the mechanical interlock and allows the control panel door to open without disconnecting power switch is in the power On position a Obtain a small standard head screwdriver b Insert the head of the screwdriver into the slotted release located on the right hand side of the disconnect faceplate Figure 129 Tu...

Page 114: ...wiring connections at the VFD analog inputs The controller displays and controls to the lower of the two readings If a sensor is defective and inputs 0 volts to the VFD the static pressure reading on the keypad display reads 0 and the controller attempts to increase the 0 value to set point by ramping the VFD up If a second sensor SPS2 is not installed or the pressure tubing to it is not connected...

Page 115: ... 193408201 MT3042 Com Module BACnet MS TP 202 DAC 193408301 MT3044 Com Module Modbus RS485 x2 193408401 MT3045 Remote Support Module 193408501 MT3 Service Cable 80 cm 193408601 MT3 Service Cable 150cm 193408701 MT3 Local HMI Cable 80 cm 193408801 MT3 Local HMI Cable 150cm 193408901 MT3 Real Time Clock Battery 200 Days 193409001 MT3 Conn Set Ctrl Spring Top Entry 193409101 MT3 Conn Set Ext 1 Spring...

Page 116: ...ories and issuance of credits All parts shall be returned to the factory designated on the return goods tag transportation charges prepaid The return of the part does not constitute an order for replacement A purchase order for the replacement part must be entered through your nearest McQuay representative The order should include the component s part number and description and the model and seria...

Page 117: ...n and this warranty shall expire twelve 12 months from that date Exceptions 1 If free warranty labor is available as set forth above such free labor does not include diagnostic visits inspections travel time and related expenses or unusual access time or costs required by product location 2 Refrigerants fluids oils and expendable items such as filters are not covered by this warranty 3 This warran...

Page 118: ...______________________________ Serial number ___________________________________ Compressor 6 model number ________________________________________ Serial number ___________________________________ Circle Yes or No If not applicable to the type of unit circle N A I INITIAL CHECK A Is any shipping damage visible Yes No N A B Are fan drives properly aligned and belts properly adjusted Yes No N A C T...

Page 119: ...______ psig Circuit 2 __________ psig Liquid press fully loaded 2 3 compressors at liquid line shutoff valve Circuit 1___________ psig Circuit 2 __________ psig Liquid temperature fully loaded 2 3 compressors Circuit 1___________ psig Circuit 2 __________ psig G System oil pressure oil pressure suction net oil pressure on four compressor units indicate for each compressor Circuit 1___________ psig...

Page 120: ...N A M Low Gas Pressure Switch OK Yes No N A N Main Gas Valve Close off OK Yes No N A VIII OIL BURNER CHECK TEST START A Nozzle s Type manufacturer GPH Angle Pattern manufacturer B Nozzle pressure _______________________ psi C CO2 __________________________ D Smoke spot number ______________ E Running amps ________________ FLA F Flame safeguard microamps_________________ G High limit control OK Yes...

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Page 122: ...n 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 Refer to Form 933 43285Y To find your local McQuay Representative go to www mcquay com This document contains the most current product informat...