McQuay Skyline IM 777-6, Installation And Maintenance Manual

Page 1: ... Installation and Maintenance Manual IM 777 6 Skyline Air Handler Group Applied Air Systems Part Number IM 777 Date October 2011 2011 McQuay International Models OAC OAH 003G 090G ...

Page 2: ...g Coils 14 Drain Pan Traps 14 Internal Isolation Assembly Adjustment 15 Electrical Installation 17 Wiring 17 Operation Guidelines 18 Startup Checks 18 Before Starting the Unit 18 Fan Wheel Alignment 19 Operating Limits 21 Fan Vibration Levels 22 Vibration Causes 22 Service and Maintenance 23 Periodic Maintenance 23 Ball Bearing Lubrication 23 Motor Bearings 23 Fan Shaft Bearings 23 Fan Drive 24 VM...

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: ...on 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 Section Rigging Curb Mounting and Unit Leveling Do not place a Skyline unit over an open curb unless it is equipped with a curb ready base I...

Page 6: ...using the 3 8 16 5 bolts located in the splice kit provided with the unit Figure 7 a To fasten two shipping sections together four bolts are needed two on each side of the unit The bolts are run from one base rail into the other and fastened with a nut Complete each section bottom and top before attaching additional sections b If desired shipping sections for non curb ready units can be fastened t...

Page 7: ...ollow instruction drawing included in the 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 t...

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: ...nstallation information in ASHRAE handbooks Observe all local codes and industry standards Do not apply undue stress at the connection to coil headers always use a backup pipe wrench Support pipework independently of the coils Water Cooling Coils Note Use glycol in water coils for outdoor air handlers Power failures and other mechanical issues can expose coils to freezing temperatures Water supply...

Page 12: ... bucket traps Use thermostatic traps only for air venting Use bucket traps for on off control only Locate traps at least 12 inches below the coil return connection Multiple coil installation individually trap each coil or group of coils Coils in series use separate traps for each coil or a bank of coils Coils in parallel a single trap can be used but an individual trap for each coil is preferred D...

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 breaker to permit the coil to drain during shutdown 5TA 8TA or 5HA coils Conden sate is lifted ...

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: ...ighten the cap screw when adjustments are completed For models 040 through 090 the isolators should be at equal For models 040 through 090 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 Turn the adjustment nut below the fan frame to lower or raise the fan...

Page 16: ...o s i t i o n n u m b e r s D 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 ...

Page 17: ...ures to ensure that power can not be energized For variable frequency drives or other energy storing 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 risqu...

Page 18: ...ge 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 moteur doivent être faits conformément aux codes d installations électr...

Page 19: ...tscrews Figure 30 Wheel to Inlet Funnel Relationship 13 to 36 Plenum Fans Table 3 Wheel to Inlet Funnel Relationship Airfoil Type Airfoil Unit sizes 003 to 035 Unit sizes 040 to 090 Dia A in A mm B in B mm Dia A in A mm A in B mm 13 22 4 56 116 0 21 5 33 20 00 7 19 183 0 31 7 87 14 56 5 06 129 0 21 5 33 22 25 7 69 195 0 33 8 38 16 18 5 62 143 0 21 5 33 24 50 8 56 217 0 31 7 87 17 69 6 90 175 0 22 ...

Page 20: ...ns Except Belt Drive Plenum Fans Wheel Funnel Parameters Size A B C 40 0 82 2 00 4 88 44 0 91 2 25 5 50 49 1 00 2 50 5 50 54 1 10 2 50 5 50 60 1 23 3 00 5 50 Fan Size Setscrew Size Torque ft lb Aluminum Steel 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 Cross Section Reference B C A FUNNEL END TO FAN WHEEL OPENING EQUALLY SPACED AR...

Page 21: ...que in lb 350 400 450 500 600 650 700 750 800 850 1000 1500 Fan speed rpm 500 400 350 300 250 200 550 900 FC20 00 F C 3 6 0 0 F C 3 3 0 0 F C 3 0 2 5 F C 2 7 6 2 F C 2 5 0 0 FC22 38 300 250 200 150 100 90 80 70 60 50 750 800 850 900 1000 1500 2000 Fan speed rpm 40 35 30 AF24 00 AF21 56 AF19 69 AF16 19 AF14 56 AF13 22 2500 3000 3500 4000 4500 350 400 450 Torque in lb Table 11 Unit Sizes 040 to 090 ...

Page 22: ... Motor imbalance 6 Fan section not supported evenly on foundation Table 12 Operating Limits Plenum Fans Fan operating limits Plenum fans Diameter 13 5 15 16 5 18 25 20 22 25 24 5 27 30 33 36 5 40 25 44 50 49 54 25 60 Class 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Maximum rpm 3 909 3 468 2 820 2 930 2 674 2 403 2 183 1 860 1 783 1 620 1 465 1 329 1 202 1 091 986 891 Maximum motor HP 7 5 10 15 15 15 20 25 30...

Page 23: ... F safe operating temperature See below for specific recommended lubricants Table 15 Recommended Lubricants and Amounts for Fan Motor Bearings Mfr Grease NEMA Size Amount to Add oz Texaco Polystar or Polyrex EM Exxon Mobile or Rykon Premium 2 or Penzoil Pen 2 Lube 56 to 140 0 08 140 0 15 180 0 19 210 0 30 250 0 47 280 0 61 320 0 76 360 0 81 400 1 25 440 2 12 CAUTION For safety stop rotating equipm...

Page 24: ...oosening the belt tension and increasing 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 setscr...

Page 25: ...screws E 9 Put on belts and adjust belt tension Do not force belts over grooves See Fan Drive Belt Adjustment page 28 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...

Page 26: ... 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 19 7 Replace belts and adjust the...

Page 27: ...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 28: ... 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 29: ... 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 Periodic cleaning is necessary to prevent this buildup from plugging the drain and causing the drain pan to overflow Also keep the drain pans clean to prevent the spread of disease Cleaning should be performed by qualified personnel F i l t e r F r a m...

Page 30: ...that hold the neoprene canvas in place around the discharge opening 4 Disconnect the fan sled from each of the corner mounts and pull the entire assembly out the side of the unit 5 After the fan sled is out loosen the fan bearings and pull out the shaft 6 Disconnect the fan housing from the fan sled and bearing support by removing the attaching bolts 7 Replace the new fan reconnect the shaft and b...

Page 31: ...oil 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 and Installin...

Page 32: ...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 33: ... 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 34: ...tened all setscrews on pulleys 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 al...

Page 35: ...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 36: ...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...

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Page 38: ...k 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 Refer to Form 933 430285Y To find your local McQuay Representative go to www mcquay com This document contains the most current product info...