McQuay RDS 802C Installation Manual

© 2004 McQuay InternationalRoofPak™ Applied Rooftop SystemsAir HandlerRAH 047C–077C12000 to 50000 cfm RDS 800C–802C4000 to 20000 cfmInstallation and M

8 McQuay IM 487-4IntroductionControl Panel The unit control panels and their locations are shown in the following figures. These figures show a typica

98 McQuay IM 487-4Check, Test, and Start ProceduresMounting and Adjusting Motor SheavesFigure 110. VM and VP variable pitch sheavesVM and VP Variable

McQuay IM 487-4 99Check, Test, and Start Procedures9Before starting the drive, make sure that all keys are in place and all setscrews and all capscrew

100 McQuay IM 487-4Check, Test, and Start ProceduresFigure 113. MVP variable pitch sheaves (type A-B)2 L o c k i n gS c r e w s" A "E n d

McQuay IM 487-4 101Final Control SettingsFinal Control SettingsWhen all start-up procedures are completed, set the controls and program the MicroTech

102 McQuay IM 487-4Final Control SettingsFigure 114. Keypad accessible menu structureKeypad accessible menu structureSub MenusSystem1 2 3UnitStatus= _

McQuay IM 487-4 103Final Control SettingsFigure 114. Keypad accessible menu structure (continued)CCB1 ID= _____[2=1]Daily Schedule5 6Mon= 00:00 - 00:0

104 McQuay IM 487-4Final Control SettingsFigure 114. Keypad accessible menu structure (continued)Active Alarm 1Alarm NameAlarm Typedd-mmm-yy hh:mm:ssM

McQuay IM 487-4 105MaintenanceMaintenanceInstallation and maintenance must be performed only by qualified personnel who are experienced with this type

106 McQuay IM 487-4Maintenancepreventive compound. Pay close attention to fan shafts, sheaves, bearings, and bearing supports,Cabinet SectionsOnce a m

McQuay IM 487-4 107MaintenancePropeller ExhaustFor more information, see page 89.Vibration LevelsEach unit as shipped is trim balanced to operate smoo

McQuay IM 487-4 9IntroductionFigure 9. Typical main control panel, 800C to 802C, 460 voltR24 R25 R28R20 R26 R27 R28R30R45R60R69R58GCB1ResistorkeypadRe

108 McQuay IM 487-4MaintenanceFigure 115. Return fan assemblySupply Fan Wheel-to-Funnel AlignmentIf the unit is equipped with an airfoil or backward c

McQuay IM 487-4 109MaintenanceFigure 120. 44" and 49"SWSI airfoil wheel-to-funnel alignmentExperience in the field has shown that R-407C sys

110 McQuay IM 487-4MaintenanceCircuit BreakerCircuit breakers are installed upstream of all VFDs to provide short circuit protection.To reset a trippe

McQuay IM 487-4 111MaintenanceTerminalsThe terminals are spring clamp type. They only require inserting (see in Figure 124) and clamping the wire to

112 McQuay IM 487-4Replacement Parts ListReplacement Parts ListComponent designationDescription McQuay part numberMCB Main Control Board 060006101CCB1

McQuay IM 487-4 113Service and Warranty ProcedureService and Warranty Procedure Replacement PartsWhen writing to McQuay for service or replacement par

114 McQuay IM 487-4Limited Product Warranty (North America)Limited Product Warranty (North America)McQuay International (“Company”) warrants to contra

McQuay IM 487-4 115

116 McQuay IM 487-4

McQuay IM 487-4 117

10 McQuay IM 487-4IntroductionFigure 10. Typical main control panel, 047C, 460 volt

13600 Industrial Park Boulevard, Minneapolis, MN 55441 USA (612) 553-5330McQuay Training and DevelopmentNow that you have made an investment in modern

McQuay IM 487-4 11IntroductionFigure 11. Typical main control panel, 077C, 460 volt

12 McQuay IM 487-4IntroductionFigure 12. Typical gas heat panel, 1000 MBHFigure 13. Typical propeller exhaust panel, three fans, 460 voltFigure 14. VF

McQuay IM 487-4 13IntroductionFigure 16. Electric heat panel, 047C Figure 17. Electric heat panel, 077CGLG3DS3M41M43FB41FB42FB43H53TB11M31M32M33FB31FB

14 McQuay IM 487-4IntroductionFigure 18. Harness plug connector detailLT OP1 LT OP2LT11LT10DFRH DFLH OPEN4SD1 SD2GSHT1 GSHT2HL22 OPEN3OAE PC7PC5ACT3 O

McQuay IM 487-4 15IntroductionControls, Settings, and FunctionsTable 2 below lists all of the unit control devices. Included in the table are the devi

16 McQuay IM 487-4IntroductionMechanical InstallationThe installation of this equipment shall be in accordance with the regulations of authorities hav

McQuay IM 487-4 17IntroductionFigure 20. Service clearances, unit with SWSI plenum supply fanVentilation ClearanceBelow are minimum ventilation cleara

ContentsMcQuay and MicroTech II are registered trademarks of McQuay International.Microsoft is a registered trademark of Microsoft Corporation.Windows

18 McQuay IM 487-4IntroductionOverhead Clearance1 Unit(s) surrounded by screens or solid walls must have no overhead obstructions over any part of the

McQuay IM 487-4 19IntroductionRoof Curb Assembly and InstallationLocate the roof curb and unit on a portion of the roof that can support the weight of

20 McQuay IM 487-4IntroductionFigure 23. RAH roof curb assembly instructionsFigure 24. Roofing detail “B”DReturnAirFBFE"X"Inside87.00"(

McQuay IM 487-4 21IntroductionFigure 25. RDS roof curb assembly instructionsDReturnAirFBFE"X"Inside"Y"Inside85.00"(2159 mm)62

22 McQuay IM 487-4IntroductionFigure 26. Typical power wire entrance, curb view (RDS 800–802 shown; for exact values, refer to submittal)Post and Rail

McQuay IM 487-4 23IntroductionRigging and HandlingLifting brackets with 2" (51 mm) diameter holes are provided on the sides of the unit.Use sprea

24 McQuay IM 487-4IntroductionLifting PointsTo determine the required lifting cable lengths and whether four-or six-point lifting is required, use Tab

McQuay IM 487-4 25IntroductionSplit UnitsAlthough units typically ship from the factory as complete units, they can be factory split at the supply fan

26 McQuay IM 487-4IntroductionPhase II. Reassemble cabinet (Figure 31)1 Reinstall top cap removed in Phase I, Step 1.2 Caulk (watertight) ends of spli

McQuay IM 487-4 27IntroductionPhase III. Reconnect power and control wiringOnce the sections are physically reconnected, the ends of the power harness

McQuay IM 487-4 1IntroductionIntroductionThis manual provides general information about the “C” vintage McQuay RoofPak applied rooftop unit, models RD

28 McQuay IM 487-4IntroductionPiping Recommendations1 Use type K or L clean copper tubing. Thoroughly clean or braze all joints with high temperature

McQuay IM 487-4 29IntroductionCharging the SystemUnits are leak tested at the factory and shipped with a nitrogen holding charge. If the holding charg

30 McQuay IM 487-4IntroductionRefrigerant ChargeFactory-installed DX coils are designed to use R-22. The total charge per circuit is the sum of the fo

McQuay IM 487-4 31Introduction• Because drain pans in any air conditioning unit have some moisture in them, algae, etc. will grow. Periodically clean

32 McQuay IM 487-4IntroductionHot Water PipingHot water coils are provided without valves for field piping or piped with three-way valves and actuator

McQuay IM 487-4 33IntroductionFigure 36. Two-way valve packageSteam Piping Recommendations1 Be certain that adequate piping flexibility is provided. S

34 McQuay IM 487-4IntroductionSteam Coil Freeze ConditionsIf the air entering the steam coil is below 35°F (2°C), note the following recommendations:1

McQuay IM 487-4 35IntroductionTable 11: Piping connection sizes/valve size options for chilled water pipingCabinet sizeApplication codeCoil size Hx 83

36 McQuay IM 487-4IntroductionTable Available Circuiting LegendColumn 1:These units are available with a factory installed package consisting of a th

McQuay IM 487-4 37IntroductionVestibule Assembly InstructionsAn accessory vestibule is available to provide additional piping space for coils installe

2 McQuay IM 487-4IntroductionTypical Component Locations Figure 2 shows a typical blow-through unit with the locations of the major components. Figure

38 McQuay IM 487-4IntroductionStep 31 Assemble side panels A and B to uprights using #10 drill screws supplied. Make certain side panels are flush aga

McQuay IM 487-4 39IntroductionDamper AssembliesThe optional damper assemblies described in this section normally are ordered with factory-installed ac

40 McQuay IM 487-4IntroductionIntake Hood Damper (0% to 100% outside air, RAH 47–77 only)Units requiring 100% outside air are provided with a rain hoo

McQuay IM 487-4 41IntroductionMixing Box (RAH 47–77 only)This section uses an outside air damper and a return air damper. Using these dampers allows o

42 McQuay IM 487-4IntroductionFace and Bypass DampersFace and bypass dampers are available in a flat arrangement for use with heating coils and standa

McQuay IM 487-4 43IntroductionFigure 51. Face and bypass dampers, flat arrangement—RAH 47–77 onlyCabinet Weather ProtectionThis unit ships from the fa

44 McQuay IM 487-4IntroductionInstalling DuctworkOn bottom-supply/bottom-return units if a McQuay roof curb is not used, installing contractor should

McQuay IM 487-4 45IntroductionInstalling Duct Static Pressure Sensor TapsFor all VAV units, duct static pressure taps must be field installed and conn

46 McQuay IM 487-4IntroductionInstalling Building Static Pressure Sensor TapsIf a unit has direct building static pressure control capability, you mus

McQuay IM 487-4 47Electrical InstallationElectrical InstallationField Power WiringAll of the unit side panels are hinged. Do not mount disconnect swit

McQuay IM 487-4 3IntroductionFigure 3. Draw-through configuration with SWSI supply fan (unit size 077C shown)Bottom return air openingOptional outside

48 McQuay IM 487-4Electrical InstallationFigure 57. Optional side power wiring entrance• The preferred entrance for power cables is through the botto

McQuay IM 487-4 49Electrical InstallationAll UnitsThe minimum circuit ampacity (wire sizing amps) is shown on the unit nameplate. Refer to Table 13 on

50 McQuay IM 487-4Electrical InstallationField Control WiringUnits are available with several control arrangements which may require low voltage field

McQuay IM 487-4 51Preparing Unit for OperationPreparing Unit for OperationFigure 61. RAH spring mount hold down fastenersSpring Isolated FansReleasing

52 McQuay IM 487-4Preparing Unit for OperationAdjusting Scroll DampersTwo sets of scroll dampers are provided in the housing of the twin 15" x 6&

McQuay IM 487-4 53Preparing Unit for OperationAdjusting Seismic RestraintsSpring-mounted supply air and return air fans can be ordered with factory-in

54 McQuay IM 487-4Sequences of OperationSequences of OperationThe following sequences of operation are for a typical “C” vintage applied rooftop unit

McQuay IM 487-4 55Sequences of OperationFan OperationWhen the main control board (MCB) commands the supply and return fans to start, the unit enters t

56 McQuay IM 487-4Sequences of OperationHeatingGas Furnace, Modulating Burner (3 to 1 turn down)Refer to “Standard Mod, furnace control (1000 MBH)” on

McQuay IM 487-4 57Wiring DiagramsWiring DiagramsLegendID Description Standard locationACT3, 4 Actuator motor, economizer Economizer sectionACT5 Actua

4 McQuay IM 487-4IntroductionFigure 4. Combination draw-through/blow-through with DWDI supply fan)Bottom return air openingCondensatedrain connectionB

58 McQuay IM 487-4Wiring DiagramsM10 Contactor, supply fan Main control boxM20 Contactor, return fan Main control boxM29 Contactor, burner motor Gas h

McQuay IM 487-4 59Wiring DiagramsT9 Transformer, refrig. circuit 24V Main control boxTB1 Terminal block, internal Main control boxTB2 Terminal block,

60 McQuay IM 487-4Wiring DiagramsFigure 67. Power package only, main powerELECTRICALCIRCUIT #1CUSTOMERSUPPLIEDPOWER10010110210310410510610710810911011

McQuay IM 487-4 61Wiring DiagramsFigure 68. Power package only, main power, continued/4.00/2.00/2.00HSAF-1HSAF-2HSAF-3HRAF-1HRAF-2HRAF-313513613713813

62 McQuay IM 487-4Wiring DiagramsFigure 69. Power package only, control power/1.68 /1.68H237-3H265-1H235-5H237-4H265-2SUPPLY AIRSMOKE DETEKTOR(24 VOLT

McQuay IM 487-4 63Wiring DiagramsFigure 70. Power package only, control power, continued(S.A. FAN AUX CONTACT)NOTE: THESE CONTACT ARE FOR USE IN A 24

64 McQuay IM 487-4Wiring DiagramsFigure 71. VAV fan power (with SAF and RAF VFDs and manual bypass)H140ELECTRICALCIRCUIT #1CUSTOMERSUPPLIEDPOWERHSAF-1

McQuay IM 487-4 65Wiring DiagramsFigure 72. VAV fan power (with SAF and RAF VFDs and manual bypass), continued/8.00/6.00/4.00/3.00/2.66/2.00/8.00/2.00

66 McQuay IM 487-4Wiring DiagramsFigure 73. CV fan power (SAF and RAF)HSAF-1HSAF-2HSAF-3ELECTRICALCIRCUIT #1CUSTOMERSUPPLIEDPOWER106107108109110111112

McQuay IM 487-4 67Wiring DiagramsFigure 74. CV fan power (SAF and RAF), continued/8.00/4.00/3.00/2.00/8.00/2.00HRAF-1HRAF-2HRAF-3144145146147148149150

McQuay IM 487-4 5IntroductionTypical Unit SectionsThe individual sections that make up a rooftop can vary from unit to unit. All available sections ar

68 McQuay IM 487-4Wiring DiagramsFigure 75. VAV control inputs/1.68 /1.68H228-1H229-2DRN-4CONTACT MUST BE OPENDURING NORMAL OPERATIONTO CCB1H231-1H232

McQuay IM 487-4 69Wiring DiagramsFigure 76. VAV control inputs, continued/8.01/4.00/3.00/1.68H252-2H25O-SRH250-4H25O-+H252-1H262-8H261-10DRN-13H264-6H

70 McQuay IM 487-4Wiring DiagramsFigure 77. CV control inputs/1.68 /1.68H220-1H221-2DRN-4H225-1H226-4H226-2NOTES TO FIELD:1. REFER TO I.M. FORMICROTEC

McQuay IM 487-4 71Wiring DiagramsFigure 78. CV control inputs, continued/1.68/8.01/3.00OPEN BINARYINPUTOPEN BINARYINPUTH243-4H244-2H245-3DRN-1H252-2H2

72 McQuay IM 487-4Wiring DiagramsFigure 79. Control actuator outputs (CV, stream, or hot water, plus economizer)/1.68/2.68/4.00 /4.00NOTES TO FIELD:1.

McQuay IM 487-4 73Wiring DiagramsFigure 80. Control actuator outputs (CV, stream, or hot water, plus economizer), continuedH365-1H366-3H969H968H964H96

74 McQuay IM 487-4Wiring DiagramsFigure 81. VFD control (SAF and RAF)/1.68/2.68 /3.11 /3.11H425-12H426-4H426-6H426-3H429-10H425-2H426-1H427-9H431-7H42

McQuay IM 487-4 75Wiring DiagramsFigure 82. VFD control (SAF and RAF), continuedH443-4H443-1H443-7H443-14H443AH443-5H443-2H443-12H443-15H443C435436437

76 McQuay IM 487-4Wiring DiagramsFigure 83. Super Mod gas furnace control (1000 MBH)/1.68H633-9H632-9H634-8NOTE:1.POWER, PILOT & MAIN VALVE INDICA

McQuay IM 487-4 77Wiring DiagramsFigure 84. Super Mod gas furnace control (1000 MBH), continuedOVER 1/2 P.S.I.SHUTOFFSHUTOFFPIPING DIAGRAM(THRU 1/2

6 McQuay IM 487-4IntroductionFigure 6. Typical unit sections (draw-through with SWSI supply fan)Note: Views shown for 047C family. Not to scaleECONO/R

78 McQuay IM 487-4Wiring DiagramsFigure 85. Standard Mod, furnace control (1000 MBH)/1.68H634-8H633-9H632-9NOTE:1.POWER, PILOT & MAIN VALVE INDICA

McQuay IM 487-4 79Wiring DiagramsFigure 86. Standard Mod, furnace control (1000 MBH), continuedPRESS. REG.PRESS. REG.AIRSWITCHAIRSWITCHCONN.TESTCOCKTE

80 McQuay IM 487-4Wiring DiagramsFigure 87. Electric heat control5005015025035045055065075085095105115125135145155165175185195205215225235245255265275

McQuay IM 487-4 81Wiring DiagramsFigure 88. Electric heat control, continuedHEATERBANK "A"M311 AM322 AM333 A120 KWHEATERBANK "B"M4

82 McQuay IM 487-4Wiring DiagramsFigure 89. Fan control, power package only/1.68SUPPLY FAN ON/OFFRETURN FAN ON/OFF400401402403404405406407408409410411

McQuay IM 487-4 83Wiring DiagramsFigure 90. CV fan control (SAF and RAF)Figure 91. Light and receptacle power401A404A426C426B426A431ATB242TB2452R68102

84 McQuay IM 487-4Unit OptionsUnit OptionsEnthalpy ControlOutside Air Enthalpy Control (OAE)Units with MicroTech II control and an economizer come sta

McQuay IM 487-4 85Unit OptionsSmoke and Fire ProtectionMcQuay optionally offers factory installed outdoor air, return air, and exhaust air dampers as

86 McQuay IM 487-4Unit OptionsDuct High Pressure LimitThe duct high pressure limit control (DHL) is provided on all VAV units. The DHL protects the du

McQuay IM 487-4 87Unit OptionsVariable Frequency Drive OperationRefer to the vendor instructions supplied with the unit.Convenience Receptacle/Section

McQuay IM 487-4 7IntroductionControl LocationsAll controls are optional. If controls are ordered, Figure shows the locations of the various control c

88 McQuay IM 487-4Unit OptionsFigure 96. Tape fulcrum alignment plate to vane9 Locate and install the fulcrum used in the leveling procedure as follow

McQuay IM 487-4 89Unit OptionsMaking Level AdjustmentsThe DesignFlow unit is mounted so that it pivots at the top when three lock nuts are loosened, t

90 McQuay IM 487-4Unit OptionsPropeller Exhaust Fan OptionEconomizer units may include propeller exhaust or centrifugal return fan options. This secti

McQuay IM 487-4 91Unit OptionsFigure 103. Belt adjustment Figure 104. Drive pulley alignmentFigure 105. Propeller exhaust fan replacement parts listB

92 McQuay IM 487-4Unit OptionsBearingsBearings are the most critical moving part of the fan and should be inspected at periodic intervals. Locking col

McQuay IM 487-4 93Unit OptionsUltraviolet Light OperationRefer to the wiring schematic below. 115 VAC power for the UV lights is provided by control c

94 McQuay IM 487-4Check, Test, and Start ProceduresCheck, Test, and Start ProceduresAll units are completely run tested at the factory to promote prop

McQuay IM 487-4 95Check, Test, and Start ProceduresNote:If desired, you can significantly reduce all MicroTech II internal control timers by the chang

96 McQuay IM 487-4Check, Test, and Start ProceduresHeating System Start-upGeneral1 At the keypad, set the heating setpoints high enough so that the co

McQuay IM 487-4 97Check, Test, and Start ProceduresSheave Alignment Mounting:1 Verify both driving and driven sheaves are in alignment and the shafts