McQuay Skyline OAC 003G, Installation And Maintenance Manual

Page 1: ...Installation and Maintenance Manual IM 777 7 Skyline Air Handler Group Applied Air Systems Part Number IM 777 Date November 2011 2011 McQuay International Models OAC OAH 003G 090G ...

Page 2: ...Heating Coils 14 Drain Pan Traps 14 Internal Isolation Assembly Adjustment 15 Electrical Installation 17 Wiring 17 Operation Guidelines 19 Startup Checks 19 Before Starting the Unit 19 VFD Setup 20 Fan Startup 20 Fan Wheel Alignment 20 Operating Limits 23 Fan Vibration Levels 24 Vibration Causes 24 Service and Maintenance 25 Periodic Maintenance 25 Ball Bearing Lubrication 25 Motor Bearings 25 Fan...

Page 3: ... before leaving the factory Rough handling can cause misalignment or a damaged bearings or shaft Carefully inspect fans and shaft before unit installation to verify this has not happened Note Screws bolts etc for assembling sections are supplied in a bag attached to each section All necessary gasketing is applied in the factory for section to section mounting unless the unit has a curb ready base ...

Page 4: ...urfaces Belt driven fans 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 Remove belt guard when adjusting belts Reduce belt tension prior to removing or installing belts Removing or installing tensioned belts may cause per sonal injury and damage to the sheaves belts bearings or shafts Adjustable sh...

Page 5: ...ovided with a factory installed base rail and can be lifted using the 2 diameter lifting holes located in the corners of each shipping section To prevent damage to the unit cabinetry use spreader bars Position spreader bars to prevent cables from rubbing the frame or panels Before hoisting into position test lift for stability and balance Avoid twisting or uneven lifting of unit Figure 3 Unit and ...

Page 6: ...o its designed position Shipping Sections 1 Caulk all assembly joints of the unit Before joining the sections apply at least 1 4 inch diameter bead of sealant to the mating faces of the cabinet Use the splice joint as a guide for applying the sealant Figure 5 Figure 5 Apply Sealant to Mating Faces 2 Pull sections together to fasten Use straps and a ratchet to help pull the sections together secure...

Page 7: ...he assembly kit Figure 8 Frame Channel Stiffener Plates Skyline Plus Units Only Figure 9 Internal Fastening Figure 10 D Gasket Placement Detail Skyline Plus Units Only 1 Check that the sealant is compressed between the mating channels when the unit sections are joined Touch up any places where gaps are noted 2 After sections are seated tightly together slip the splice cap over the top panel flange...

Page 8: ...r on one side of the unit If requested on order doors can be provided on both sides of the unit Optional service doors are available for most section types and are provided based on customer request Fan Section Doors Note Opening fan section doors requires using a 1 2 socket wrench Figure 13 which satisfies ANSI standards and other codes that require the use of tools to access compartments contain...

Page 9: ...n occur If larger heavier components require mounting on unit panels use through bolts with flat washers through both outer and inner panels To maintain panel integrity seal both ends with an industrial commercial grade silicone sealant or duct seal compound The unit frame channel is another excellent location for securing heavier components self tapping screws are not acceptable Ensure that the l...

Page 10: ...he location of these actuators due to the number of options and arrangements available and the variety of specific applications Typically actuators are mounted inside the cabinet Provide proper support for the actuator to avoid excessive stress in the cabinet linkage or damper shafts Note Damper blades are at full flow when open to 70 degrees Do not open blades further than 70 degrees Fresh air an...

Page 11: ...or 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 Fig...

Page 12: ...open to the atmosphere and the trap design should allow venting of large quantities of air Traps Note Do not place steam traps outdoors Size traps in accordance with the manufacturers recommendations Make sure the required pressure differential is always available Do not undersize Use float and thermostatic or bucket traps for low pressure steam On high pressure steam use bucket traps Use thermost...

Page 13: ...Return main 12 min Vacuum breaker 1 2 check valve Steam main Return main 12 min Full size of return conn Check Valve Strainer Gate Valve Control valve modulating two position Float and thermostatic trap High Pressure over 25 psi Low Pressure to 25 psi 5GA or 8GA coils Note that the addition of a vacuum brea ker to permit the coil to drain during shutdown 5TA 8TA or 5HA coils Conden sate is lif ted...

Page 14: ...in pan trap to allow condensate to drain freely On both blow through and draw through units the trap depth and the distance between the trap outlet and the drain pan outlet must be twice the static pressure in the drain pan section under normal operation so the trap remains sealed Figure 22 Figure 22 Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet Note The door panels on some appl...

Page 15: ...et panel opening If adjustment is required loosen the cap screw on top of the isolator assembly Turn the adjustment nut below the fan frame to lower or raise the fan motor and frame assembly Retighten the cap screw on top of the isolator assembly Figure 24 Adjusting Large Spring Mount Assembly Table 1 Motor Beside Fan Spring Mount Adjustments Spring mount adjustment at rest Isolator position Top o...

Page 16: ... i m H S p r i n g h e i g h t a d j u s t m e n t s c r e w S p r i n g h e i g h t a d j u s t m e n t s c r e w S h i p p i n g h o l d d o w n s c r e w S h i p p i n g b r a c k e t D e t a i l A S h i p p i n g h o l d d o w n r e m o v e a n d d i s c a r d T y p i c a l 4 p l a c e s S e e d e t a i l A S h i p p i n g b r a c k e t r e m o v e a n d d i s c a r d T y p i c a l 4 p l a c e...

Page 17: ...components that have been furnished and mounted by either McQuay or by others refer to the specific manufacturer s literature for allowable waiting periods for discharge of capacitors Verify capacitors have been discharged using an appropriate voltmeter ADVERTISSEMENT Voltage de condesateur à risquee de danger À défaut de débrancher la puissance électrique et de décharger le condensateur avant de ...

Page 18: ...on the exterior of the fan section When multiple fan sections are provided with multiple VFDs they must be set up so that the fans always start simultaneously and are set to ramp up and down together Do not attempt to run fans in parallel at different speeds as this can result in uneven airflow that can cause performance sound and vibration problems that can lead to failure Provided that the fan i...

Page 19: ... la tension WARNING Fire electric shock hazard Can cause property damage personal injury or death Wire fan power supply and ground motor frame in accordance with local electric codes AVERTISSEMENT Risques d incendie et d électrocution pouvant causer des dommages matériels des blessures et même la mort L alimentation électrique du moteur du ventilateur de même que la mise à la terre du chàssis du m...

Page 20: ... to retain sheave alignment Fan Wheel Alignment Figure 29 Wheel to Inlet Tunnel Relationship Airfoil Type Fan Wheels Housed Note 1 To obtain rated air performance dimensional relationship must be held 2 To obtain dimension A loosen setscrews in wheel hub s shifting wheel s axially as needed and retightening setscrews 3 To obtain dimension B loosen screw and washer fasteners around periphery of fun...

Page 21: ...Plenum Fan Wheel Funnel Parameters Size A B C 13 0 25 0 91 3 50 15 0 25 0 91 3 50 16 0 25 0 91 3 50 18 0 38 0 86 3 88 20 0 42 1 11 3 88 22 0 45 1 11 3 88 24 0 51 1 11 3 88 27 0 55 1 36 4 50 30 0 62 1 36 4 50 33 0 55 1 50 5 00 36 0 63 1 50 5 00 Cross Section Reference C AROUND DIAMETER EQUALLY SPACED B A FROM FUNNEL END TO FANWHEEL OPENING END Wheel Funnel Parameters Size A B C 40 0 82 2 00 4 88 44...

Page 22: ... 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 2 N A 27 3 8 19 2 22 30 1 2 41 7 55 33 1 2 41 7 55 36 1 2 41 7 55 40 1 2 41 7 55 44 1 2 41 7 55 49 1 2 41 7 55 54 1 2 41 7 55 60 3 4 115 150 Wheel funnel overlap Size Overlap in 150 0 375 165 0 438 182 0 562 200 0 625 222 0 688 245 0 750 27...

Page 23: ... 1875 1691 1479 1328 1209 1073 Maximum rpm Class Il 2703 2413 2199 1928 1730 1579 1401 Table 17 Operating Limits Belt Drive Plenum Fans Fan Operating Limits Belt Drive Plenum Fans Size 13 15 16 18 20 22 24 27 30 33 36 40 44 49 54 60 Maximum rpm Class II 3909 3468 2820 2930 2674 2403 2183 1860 1783 1620 1465 1329 1202 1091 986 891 Maximum rpm Class III 4000 4000 3887 3735 3409 3065 2780 2423 2182 1...

Page 24: ...ion of potential trouble Vibration Causes 1 Wheel imbalance a Dirt or debris on wheel blades b Loose set screws in wheel hub or bearing to shaft c Wheel distorted from overspeed 2 Bent shaft 3 Drive faulty a Variable pitch sheaves Axial and radial runout of flanges uneven groove spacing out of balance Also similar faults in driven sheave b Bad V belts lumpy or mismatched belt tension too tight or ...

Page 25: ...gs are supplied with grease fittings or zerks for ease of lubrication with hand or automatic grease guns Always wipe the fitting and grease nozzle clean CAUTION Bearing overheating potential Can damage the equipment Do not overlubricate bearings Use only a high grade mineral grease with a 200 F safe operating temperature See below for specific recommended lubricants Table 21 Recommended Lubricants...

Page 26: ...or decreasing the pitch diameter of the sheave by half or full turns as required Readjust belt tension before starting drive 6 To provide the same pitch diameter adjust both halves of the two groove sheaves by the same number of turns from closed position 7 Verify that all keys are in place and that all se screws are tight before starting drive Check setscrews and belt tension after 24 hours servi...

Page 27: ...elts over grooves See Fan Drive Belt Adjustment page 30 10 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 service Adjusting 1 Slack off belt tension if belts have been installed 2 Loosen setscrews D 3 Loosen but do not remove capscrews E 4 Remove key F Note ...

Page 28: ... a Do not open B sheaves more than 4 3 4 turns for the A belts or 6 turns for the B belts b Do not open C sheaves more than 9 1 2 turns c Do not open 5V sheaves more than 6 turns d Do not open 8V sheaves more than 8 turns 6 Tighten BOTH locking screws A in the outer locking ring before operating the drive Use a torque wrench and tighten to the value shown in Table 25 7 Replace belts and adjust the...

Page 29: ...s t a b l e C e n t e r F l a n g e F i x e d C e n t e r F l a n g e S t a t i o n a r y E n d F l a n g e C a p s c r e w s D o N o t R e m o v e 2 L o c k i n g S e t s c r e w s A F l a t h 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 I n n e r L o c k i n g R i n g O u t e r L o c k i n g R i n g S p l i t T a p e r B u s h i n g 3 H o l e s f o r S p a n n e r W r e n c h o r D r i f ...

Page 30: ... the filter compartment until the fan is completely stopped Use approved equipment for reaching filters located above normal reach Do not step on filter frames or unit components Floor surfaces must be dry and free of oil or grease WARNING Pendant l installation et où l entretien des filtres une courroie en mouvement ou un ventilateur en opération peuvent causer des blessures graves où même causer...

Page 31: ...nal filters Figure 41 Filter Gauge F i l t e r F r a m e R o t a t e W i r e C l i p s P r e f i l t e r F i n a l F i l t e r Table 27 Filter Pressure Drops Bag filters DriPak 2000 Efficiency 45 65 85 95 Rated velocity fpm 625 500 500 500 Initial pressure drop 20 26 21 30 34 48 50 70 Initial pressure drop 1 0 1 0 1 0 1 0 Cartridge filters Varicel II MH 4 25 deep Efficiency 65 85 95 Efficiency Rat...

Page 32: ...nal is not responsible for the freezing of coils Removing and Replacing Components See Access Doors and Panels page 8 for instructions on removing panels and opening fan access doors to remove or replace components Removing the Fan Section The fan shaft motor and any drive components can be removed and replaced through the access door opening If required the side panel can be removed for additiona...

Page 33: ...located in the connections 2 Remove all screws and remove the access panel 3 Remove the screws holding the coil in place 4 Lift and pull the coil out the side Installing Single Coils 1 Slide the coil through the opening in the coil section onto the bottom coil rests 2 To prevent any air bypass around the coil place coils up against the coil bulkheads See Single Coil Top Installation Removal page 3...

Page 34: ...ace bolt the coil to the section 4 Caulk the mounting surface of the steel plate and install the plate on the coils 5 Caulk the mounting surface of the drain trough and install the drain trough on the coils 6 Caulk the seams between the coil casings and blockoffs 7 Connect all piping and install the brass plugs for the vents and drains located in the connections 8 Install the access panel Removing...

Page 35: ...ts 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 ...

Page 36: ... returned material Enter the required information to expedite handling and prompt issuance of credits All parts must be returned to the appropriate McQuay facility designated on the Return Goods tag Transportation charges must be prepaid The return of the part does not constitute an order for replacement Therefor a purchase order must be entered through the nearest McQuay representative The order ...

Page 37: ... bearings and fans Yes No N A D Have the hold down bolts been backed off on spring mounted fan isolators Yes No N A E With power off do fans turn freely by hand Yes No N A F Electrical service corresponds to unit nameplate Yes No N A Volts __________ Hertz __________ Phase __________ G Is the main disconnect adequately fused and are fuses installed Yes No N A H Are all electrical power connections...

Page 38: ...II HEAT RECOVERY A Heat wheel rotates freely Yes No N A B Heat wheel VFD operates properly Yes No N A C Heat wheel VFD model _____________________ serial _____________________ N A D Check for air bypass around heat wheel Yes No N A Yes No N A Yes No N A Signature ______________________________________________________ Startup date ____________________________________ RETURN COMPLETED FORM WITHIN 10...

Page 39: ...abinet have any air leakage Yes No N A Location on unit ___________________________________________________________________________ 5 Were there any refrigerant leaks Yes No N A Shipping Workmanship Design 6 Does the refrigerant piping have excessive vibration Yes No N A Location on unit ___________________________________________________________________________ 7 Did all of the electrical control...

Page 40: ...quipment 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 430285Y To find your local McQuay Representative go to www mcquay com Aftermarket Services To find your local parts office visit www mcquay com or call 800 37PARTS 800 377 2787 To find your local service office vis...