Catalog C: RoofPak Singlezone Heating and Cooling Units. Type RPS/RFS/RCS 18 to 135 Tons MEA N. See page 3

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1 Catalog C: RoofPak Singlezone Heating and Cooling Units Type RPS/RFS/RCS 18 to 135 Tons MEA N See page 3

2 A New Standard in Rooftop Systems 15 through 135 tons with the flexibility to provide 200 to 600 cfm/ton. DX or future cooling. Full factory operation test. 100% make-up air, dehumidification, VAV or CV operation. Modular construction and customized application flexibility. Multiple fan, coil, filter and heat selections, and high efficiency compressor combinations. Factory integrated and commissioned MicroTech II advanced DDC control system. McQuay s innovative Protocol Selectability provides building automation system interoperability with BACnet and LonMark communications capability. Durable, double wall construction with access doors on both sides of each section. Blow through configuration for high sensible cooling and quite operation. Draw through configuration for high latent cooling or high humidity applications. Agency Listed MEA N Nomenclature Contents McQuay s unique features and options Introduction Features and Options Variable Air Volume MicroTech II Unit Controls Application Considerations Unit Selection Physical Data Cooling Capacity Data Heating Capacity Data Component Pressure Drops Fan Performance Data - Supply Fans Fan Performance Data - Propeller Exhaust Fans Fan Performance Data - Return Fans Dimensional Data Roof Curbs Recommended Clearances Electrical Data Unit Weights Engineering Guide Specification Document Number: Cat HI-F, MicroTech II, RoofPak, Protocol Selectability, SpeedTrol, VaneTrol, DesignFlow, SuperMod, and UltraSeal are trademarks and McQuay is a registered trademark of McQuay International, Minneapolis, Minnesota. The McQuay HI-F fin surface is covered by U.S. Patent No. 3,645, McQuay International. All rights reserved throughout the world. Bulletin illustrations cover the general appearance of McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. Cat

3 McQuay s unique features and options... Modular Flexibility Allows you to specify the unit you want, optimized for high energy efficiency, good IAQ, and quiet operation. 100% make-up air, dehumidification, CV, and VAV system control provided by MicroTech II control system. Blow through configuration (shown) provides higher sensible cooling, a quiet tenant environment, and energy savings. Draw through configuration provides higher latent cooling for make-up air systems or systems with high humidity loads. Multiple filter, fan, coil, and heating options in flexible sizes to match system needs. Extended face area filters and coils reduce system pressure drops, improving operating and energy efficiency. Multiple high efficiency compressor combinations match system needs. Optional return/supply locations match system configuration requirements at lower installed costs, reduced air pressure drops, and quieter operation. Return or Exhaust Fan Customize the unit to fit the application and return duct pressure drop. Return fans typically provide better building pressure and ventilation control as return duct pressure drop increases. Exhaust fans typically save energy as return duct pressure drop increases. Factory-Mounted Variable Frequency Drives Control fan motor speed for lower fan operating costs and lower noise. MicroTech II Advanced DDC Control System Factory-installed and tested to minimize costly field commissioning. Open Protocol for direct incorporation into BACnet or LonMark systems provides maximum building automation system compatibility. Easily accessed for system diagnostics and adjustments via a keypad/display on every unit. Minimum outdoor air and humidity control logic ensure fresh air intake and optimum humidity levels. High Efficiency Condensing Section Open air design for unrestricted airflow and access to compressors and refrigerant piping. Up to 8 steps of compressor capacity control, with hot gas bypass on each circuit, provides a stable discharge temperature and humidity control. High efficiency Copeland Compliant Scroll or Discus semi-hermetic compressors provide optimum system performance and proven reliability. Economizer Outside air enters from both sides, improving mixing for better temperature control. Maintains minimum outside air intake for good IAQ. Monitors outside air conditions for "free" cooling. DesignFlow Precision Outdoor Air Measurement System accurately measures outdoor air intake. Patented UltraSeal low leak dampers minimize air leakage, reducing energy costs. Generous face area intakes/outlets and dampers reduce system pressure drops, improving operating and energy efficiency. Hinged Access Doors On both sides of every section for easy access to all components. Single lever latch and door holders provide easy entry. Double-wall construction protects insulation during maintenance. Durable Construction Pre-painted exterior cabinet panels pass ASTM B 117 Salt Spray Test for durability. Capped seams prevent water leaks into cabinet. Cross-broken top panels eliminate standing water. Heavy-duty R-6.5 insulation minimizes heat loss for reduced energy costs. Double-wall construction protects insulation and provides wipe clean surface to inhibit microbial growth. Stainless steel, sloped drain pans eliminate standing water. Full unit base rail with heavy-duty lifting lugs provide single piece rigging of units up to 135 tons. Airfoil Fans More energy efficient and improved sound performance versus forward curve fans. Double width, double inlet (DWDI) variety. Blank Sections Available throughout unit to factory-mount air blenders, carbon or charcoal filters, sound attenuators, humdifiers, or other specialty equipment (air purification system shown). Allow customization for maximum system performance and efficiency. Reduce design and installation costs. SuperMod High Turndown Gas Burner Full 20:1 turndown and multiple sizes enable precise temperature control at reduced design, installation, and life-cycle costs. Maintain comfortable tenant environment in VAV, 100% make-up air, and dehumidification applications. Note: Air Handler Configuration The benefits of McQuay s packaged rooftop system are available in a rooftop air handler configuration. For details, see Catalog Cat Cat

4 Introduction McQuay RoofPak applied rooftop systems are the semicustom, HVAC system solution for your 1 to 8 story building projects. Available with cooling capacities from 18 to 135 tons, RoofPak systems offer the installation cost and interior space savings of a roof-mounted system, while providing comparable flexibility and operating and maintenance efficiencies to central heating and cooling systems. Applications range from offices, schools and libraries, to airport terminals, manufacturing facilities, shopping malls, supermarkets, casinos, and condominiums. McQuay RoofPak systems feature the benefits of a modular design, extensive component flexibility, MicroTech II DDC controls with Protocol Selectability and a durable, completely accessible design for easy maintenance and service, and extended unit life. Modular Design Flexibility to Meet Your Application s Energy, Sound, And IAQ Requirements The unique, modular construction of McQuay Roofpak systems allows units to be configured with the features and options required for your specific installation, creating a cost-effective, customized rooftop system. Units are available for 100% make-up air, dehumidification, constant volume, or variable air volume applications. Units can be configured with the cooling coil in the Blow Through position for high sensible cooling operation, or in the Draw Through position for high latent cooling demands in specialty applications or high humidity climates. Blank sections along the length of the unit allow air blenders, carbon or charcoal filters, sound attenuators, humidifiers, and other specialty equipment to be designed-in and factory-mounted. A wide range of fan, coil, filter and heat selections, and high efficiency compressor combinations, allow the designer to optimize component selections for energy, sound, and IAQ requirements. Easy, Low Cost Installation, Maintenance, and Service McQuay RoofPak systems arrive at the job site as a complete package, factory-assembled and fully tested with controls, eliminating the need for expensive field assembly, refrigerant piping, and control installation. To promote regular maintenance for peak system performance, hinged access doors on both sides of each section, with single lever latches and door holders, put all components within easy reach for maintenance and service personnel. MicroTech II controls are easily accessed for equipment diagnostics and adjustments via a keypad/display on the unit. In addition, Protocol Selectability enables MicroTech II controls to have interoperability with today s building automation systems (BAS), including those using the BACnet or LonMark protocols, providing easy access to all unit operating data and allowing the unit to be operated along with other building systems from a central control station. Durable Construction For Long Life For durability and long life in harsh outdoor conditions, McQuay RoofPak systems feature a leak resistant cabinet design with pre-painted exterior surfaces. Full double-wall construction protects the unit s heavy duty R-6.5 insulation during maintenance and service, and provides a wipe-clean surface McQuay RoofPak Applied Rooftop System - Modular Design Flexibility and Complete Access 4 Cat 214-5

5 Features and Options McQuay RoofPak systems are built to perform, with features and options that provide for low installed costs, high energy efficiency, good indoor air quality, quiet operation, low cost maintenance and service, and longevity. Completed systems are factory tested and shipped with an ETL or ETL Canada Safety Listing. Unit Construction Nominal unit cooling capacities from 15 to 135 tons. Units up to 52 feet long can be shipped completely assembled. Weather resistant cabinet design with standing top seams and cross-broken top panels to provide positive drainage. Pre-painted exterior surfaces that withstand a minimum 0 hour salt spray test per ASTM B117. Full size, double wall hinged access doors on both sides of each section. All positive pressure door latches have a second catch to prevent the door from opening rapidly if it is opened when the fan is on. Single lever latch mechanism and door holders on each access door. Heavy-gauge galvanized steel unit base with formed recess to seat on roof curb gasket and provide positive weathertight seal. Heavy duty lifting brackets strategically placed for balanced cable or chain hook lifting. Full double-wall construction is available throughout the unit to protect R-6.5 insulation, enhance performance and satisfy IAQ requirements. Perforated liners are available in the plenum areas to enhance sound performance. Available auxiliary blank sections provide the flexibility for factory or field-installed specialty equipment. Factory-mounted and wired service lights with switch and outlet are available in each fan section. Full Double-Wall Construction Condensing Section Open design permits unrestricted condenser airflow, access to compressors, refrigeration components and piping, and access for roof maintenance. Unique rail support system allows the roof deck and insulation to help block compressor noise from entering the building. High efficiency Copeland scroll compressors (15 to ton units). High efficiency Copeland Discus semi-hermetic compressors (70 to 135 ton units). Spring compressor isolation with refrigerant line vibration absorbers available for all semi-hermetic selections. Each refrigerant circuit is furnished with an accessible sightglass, filter drier, manual shutoff valve, high pressure switch, low pressure switch, liquid line solenoid valve, TXV, manual control circuit switch, and manual pumpdown switch. All units feature dual refrigeration circuits for redundancy and efficient capacity control. Large face area condenser coils, with integral subcooling circuits, are constructed of high efficiency, enhanced copper tubing and aluminum fins, for high operating efficiencies. Vertical air discharge minimizes noise. Three-phase condenser fan motors eliminate reverse rotation failures. Up to eight steps of compressor capacity control, with hot gas bypass (on one or both circuits) provides for stable discharge temperature and humidity control. SpeedTrol head pressure control allows mechanical cooling to 0 F ambient temperatures. Part winding start provides two-step starting to reduce current inrush on large capacity compressors. Copper fin condenser coils are available for application in seacoast atmospheres. Cross wire PVC coated condenser coil guards are available to protect condenser fins. Cooling Coil Section Large face area evaporator coils with high efficiency, enhanced copper tubing and aluminum fins, provide for low air pressure drop and high full and part load operating efficiencies. All evaporator coils feature interlaced circuiting to keep the full face of the coil active and eliminate air temperature stratification. Long life painted galvanized steel or stainless steel, sloped (1/8 in./foot incline) drain pans. An intermediate drain pan in the coil bank helps to provide condensate removal without carryover. 3, 4, or evaporator coils with 8, 10, or 12 fins/inch spacing allow a custom match to specific design loads. Multiple coil face areas allow units to be properly matched to wide ranging conditions from 100% outside air to high cfm comfort cooling applications. Cat

6 Extended Face Area Coils Open drip-proof or totally enclosed motors comply with EPACT efficiency requirements. Premium efficiency motor upgrades available. All fan drives are factory sized according to job specific airflow, static pressure, and power requirements. Single width, single inlet (SWSI) airfoil return fans effectively handle high return duct static pressures and provide superior building static pressure control in VAV systems. For seismic sensitive regions, spring fan isolators are available with seismic restraints. 150% service factor drives extend service life of the fan belts. Fan motor power correction to a minimum of Fan motor and drive assembly belt guards. NA to exhaust fans (See 0 to 100% Economizer with Propeller Exhaust Fans on page 8. Variable Air Volume Control Fan Section Multiple double width, double inlet (DWDI) forward curved and airfoil supply air fan selections provide efficient, quiet operation at wide ranging static pressure and CFM requirements. Each fan assembly is dynamically trim balanced at the factory before shipment. Neoprene gasket isolates the fan housing and eliminates vibration transmission to the fan bulkhead. Solid steel fan shafts rotate in 200,000 hour, greaseable ball bearings. All fan assemblies are isolated from the main unit on RIS or 2 in. deflection spring mounts. Airfoil Fans Simple variable inlet vane control is available with all airfoil supply and return fan selections. Energy saving advanced technology variable frequency drive (VFD), fan speed control is available with the convenience and cost savings of factory mounting and testing. All VFD selections are plenum rated and are conveniently mounted within the filtered air stream for extended service life and easy accessibility to maintenance and service personnel. To manage building static pressure dedicated VFDs are used for the supply and return fans. MicroTech II controls provide advanced duct and building static pressure control and equipment diagnostics capability. Factory-Installed Variable Frequency Drive 6 Cat 214-5

7 Supply and Return Air Plenum Application flexibility of bottom, side, top and front (RFS only) discharge locations and bottom and back return locations to match complex system configuration requirements. Available with burglar bars for added security in both the discharge and return openings. Main Heat Section Wide ranging natural gas, electric, steam and hot water heat selections effectively handle almost any heating demand from morning warm-up control to full heat. Control of all heating options is fully integrated into the unit s MicroTech II control system. Gas Heat Extensive selection flexibility from 200-2,000 MBH output can satisfy wide ranging needs. Two-stage, 3:1 and patented SuperMod 20:1 modulating control provides the flexibility to solve diverse needs. All gas burners exceed ASHRAE Standard 90.1 efficiency requirement of 78% for low fire and % for high fire with efficiencies as high as 88% and % respectively. Gas burners and piping trains are U.L. approved with the complete furnace assembly ETL or ETL-Canada Listed. Special order capability with FM or IRI/FIA gas trains. All burner assemblies are factory tested and adjusted prior to shipment. Heat exchangers are a two-pass, drum-and-tube design with stainless steel primary surfaces. Air temperature rise capability of up to 100 F on most models. Burners are forced draft type with all controls and valves housed in the burner vestibule. Designed for ease of inspection, cleaning and maintenance. Patented design of integral flue improves combustion gas distribution, resulting in lower surface temperatures, reduced stresses and higher efficiencies. High-pressure regulators (2-10 psi) also available. All stainless steel heat exchangers provide long life in 100% outside air applications. Fuel lines may be conveniently routed through the curb or the burner vestibule door. Heating control fully integrated into the unit s MicroTech II control system. SuperMod High Turndown Gas Burner Full 20:1 turndown with continuous modulation between 5% and 100% of rated capacity provides precise temperature control for a comfortable tenant environment, even in demanding applications such as dehumidification, 100% make-up air and VAV systems. Solves the mixed air tempering requirements of VAV systems when meeting ASHRAE ventilation requirements at cold ambient, light load conditions. Operates at normal inlet gas pressures, throughout the entire modulation range. 14 burner sizes ranging from 200 to 2,000 MBH output capacity. Patent pending design featuring 4 unique design innovations and 37 patent claims. SuperMod 20:1 Burner Versus 3:1 Burner Electric Heat kw selections factory assembled, installed and tested. Single or multi-stage capability for application flexibility. Constructed of low watt density, nickel chromium elements for long lasting durability. Entire heat bank protected by a linear high limit control with each heater element protected by an automatic reset high limit control. Fuses provided in each branch circuit. MicroTech II controls sequence circuits for operating economy and reduced cycling wear. Steam Heat Steam heating coils are 1- or 2-row, 5/8 in. O.D. copper tube/aluminum fin jet distributing type with patented HI- F5 fin design. Rated in accordance with ARI Standard 430. Four different steam coil selections offered to size heating output to application needs. Factory-installed two-way modulating control valve, piping and modulating spring return actuator provide system control and full flow through the coil in the event of a power failure. Available with factory-mounted freezestat. Hot Water Heat Hot water coils are 1- or 2-row, 5/8 in. O.D. copper tube/aluminum fin design with patented HI-F5 fins. Multiple coil selections offered to size heating output to application needs. Factory-installed three-way modulating control valve, piping and modulating spring return actuator provide system control and full flow through the coil in the event of a power failure. Heating control fully integrated into the unit s MicroTech II control system. Available with factory-mounted freezestat. Cat

8 Figure 1: Airflow Configuration Outside/Return Air Section 100% Return Air Option Includes a return air plenum with a bottom, back or top return air opening. 0 to 30% Return Air Option Includes return air plenum and 0-30% outside air intake hood with patented UltraSeal low leak dampers to minimize leakage during off cycles. Damper is field adjusted to a fixed open position that is easily set using the MicroTech II keypad. Available with two-position or modulating control. 100% Outside Air Option Includes a weather hood factory mounted to the filter section, bird screen to prevent infiltration of foreign objects and UltraSeal low leak dampers to minimize leakage during off cycles. Dampers arranged vertically and controlled by a twoposition actuator, factory wired to sequence open when the supply fan is running and to close when the supply fan is off. Economizer Airflow 0 to 100% Economizer Option Includes return air plenum with back or bottom opening, exhaust air dampers and UltraSeal low leak economizer intake dampers to minimize leakage during off cycles. Available with or without a full return air fan. Outside air is introduced from both sides of the unit through outside and return air dampers that are arranged vertically to converge the multiple air streams in circular mixing patterns, minimizing temperature stratification and improving system performance % economizer sections use horizontal louvered intakes, eliminating unsightly hood assemblies. Economizer control is fully integrated into the unit s MicroTech II control system and features spring return actuator, adjustable minimum outside air set point and adjustable changeover. DesignFlow outdoor air control system measures outside air intake volume and automatically adjusts damper position to maintain minimum volume requirements. Outside air enthalpy, comparative enthalpy or dry-bulb temperature changeover provides control flexibility to bring in the most economical amount of outside air for free cooling. Exhaust dampers exhaust air out the back of the unit. 0 to 100% Economizer with Centrifugal Return Fan Figure 1 shows return fan air flow configuration. All 0 to 100% economizer components are included Includes a DWDI forward curved or SWSI air foil, centrifugal return fan Return fans are in series with the supply, and operate simultaneously with the supply fan to control building pressure, and handle the return duct ESP at all times. Return fans and exhaust fans have different performance characteristics and are not interchangeable. See page 25 for application recommendations. 0 to 100% Economizer with Propeller Exhaust Fans Figure 2 on page 9 shows exhaust fan air flow configuration. All 0 to 100% economizer components are included Includes one to three propeller fans, depending on required capacity, all controlled from one VFD. exhaust fans are in parallel with the supply fan, and may only operate during the economizer mode to control building pressure, and do not handle the return duct ESP design. Return fans and exhaust fans have different performance characteristics and are not interchangeable.see page 25 for application recommendations. 8 Cat 214-5

9 Figure 2: Airflow Configuration - Return Fan Multiple Filter Options - N D = K I J 4 A JK H 5 K F F O DesignFlow Precision Outdoor Air Control System Patent pending, precision mass flow sensor assemblies directly measure the total mass volume of air flowing through the outdoor air intakes with accuracy exceeding 95% Repeatable accuracy helps provide adequate ventilation air for good indoor air quality (IAQ), energy efficiency and compliance with ASHRAE Standard See Table 1 for ventilation airflow measurement ranges verified by Intertek Testing Services, Inc. Table 1: Ventilation Airflow Measurement Range Unit Size 015C-030C 036C-040C 045C-0C 0C-135C Pre-engineered, factory-installed and calibrated system requires no additional field-installed devices or complicated field calibration. MicroTech II controls automatically respond to mass flow sensor signals and adjusts outdoor air damper position to maintain ventilation rate set point. Filter Section Ventilation Airflow Measurement Range 540-9,400 cfm 8-13,120 cfm 10-18,000 cfm ,126 cfm Selection flexibility includes large face area angular filter racks with 2 in., 30% panel filters, or high efficiency cartridge filter assemblies with pre-filters. Multiple access doors allow easy filter changes from either side of the unit. 65% and 95% efficient filter selections feature permanent gaskets to seal against the cartridge filters and include a 2 in., 30% pre-filter. Extended filter face area arrangements meet a wide range of airflow requirements. Double wall, 95% efficient final filter selections are available as the last section before the discharge plenum. Static Air Mixers Factory installed between the outside/return air section and the filter section. Provides blended air temperatures to minimize the potential for freezestat trips when using a hydronic heating source. Blended outside/return air streams improve system control and avoid uneven temperature distribution at the duct take-offs. Sound Attenuators Factory-installed downstream of the supply fan to dampen fan noise in sound sensitive applications. Can reduce sound levels by as much as half in the lower octave bands and more than half in the higher octave bands. Tedlar coating available for added protection of the acoustic insulation. Factory Installed Sound Attenuators Cat

10 Humidifiers Factory installed steam humidifier distribution grids downstream of the supply air fan. Unit Controls Integrated advanced MicroTech II DDC controls with unit mounted human interface featuring a 4-line, 20 character English display for fast equipment diagnostics and adjustments. Controls factory installed and commissioned prior to shipment. 100% make-up air, dehumidification, VAV, or CV control capabilities. Factory integrated minimum outdoor airflow measurement and control capability. Protocol Selectability allows interoperability with today s BAS, including those using the BACnet and LonMark protocols. MicroTech II Keypad/Display Electrical Units are completely wired and tested at the factory, with control wiring routed in an accessible, protective wire raceway at the base of the unit. Wiring complies with NEC requirements and all applicable U.L. standards. For ease of use, wiring and electrical components are number coded and labeled according to the electrical diagram. Units have a 115V convenience receptacle. Supply and return air fan motors, compressor motors, and condenser fan motor branch circuits are individually fused. A single point power connection with power block or disconnect switch is standard. A unit mounted disconnect includes a service handle on the exterior of the control panel door. Electrical power feeds inside the perimeter roof curb through factory provided knockouts in the bottom of the main control panel. Dual disconnects are available on size 045C-135C units to satisfy emergency power requirements. Supply and return fan motors and controls are on the emergency power circuit and the balance of the unit is on the other. Phase failure/under voltage protection is available to protect three phase motors. Roof Curbs Constructed in accordance with NRCA guidelines with 12-gauge galvanized steel. Fits inside the unit base around the perimeter of air handling section. Duct frames are provided as part of each curb assembly to allow duct connections to be completed before the unit is placed. Gasket seals between the curb duct frame and the unit. Separate, factory-supplied steel rail supports condensing section to isolate noise and vibration from the air handling section, and to allow open roof access under the condensing section. 10 Cat 214-5

11 Variable Air Volume McQuay RoofPak variable air volume systems (VAV) employ the concept of varying the air quantity to a space at a constant temperature thereby balancing the heat gains or losses and maintaining the desired room temperature. This true variable volume system is commonly referred to as a squeeze-off or pinch-off system. Unlike a bypass or dump system, supply air is diverted from areas where it is not required to areas that need cooling and at system part load conditions the total fan volume is reduced. This ability to reduce supply air quantities not only provides substantial fan energy savings at partial load conditions, but it also minimizes equipment sizing. The minimum air volume capability of an inlet vane application is also difficult to determine. Whenever a VAV system with terminal boxes is controlled by a static pressure sensor, a system resistance curve is developed which passes through the design operating point and a minimum static pressure control point. This system curve determines where the fan crosses into its unstable operating region. Figure 3 illustrates inlet vane turndown. The following equation calculates the minimum airflow (turndown) available. Figure 3: Min. cfm= ( cfm 1 ) Inlet Vane Turndown SP cfm 1 SP SP cfm 2 SP 1 3 1/ 2 Variable volume systems offer the following advantages: 1. Lowers system first cost by using system diversity to reduce equipment and duct sizes. 2. Lowers operating costs by reducing fan energy demands, especially at part load conditions. 3. Lowers first cost by reducing space requirements for duct trunks and mechanical equipment. 4. Provides system flexibility to match changing occupancy demands. Two effective means for modulating air delivery are available with the RPS and RFS units. These VAV options include variable inlet vanes and variable frequency drives. Both means offer reliable operation over a wide range of airflow, with variable frequency drives offering advantages in sound and energy performance. Inlet Vanes Fan volume reduction with inlet vanes is accomplished by pre-spinning the air in the direction of fan rotation. The effect of pre-spinning results in decreased airflow, decreased static pressure and decreased fan brake horsepower. For each position of a variable inlet vane, a new fan curve is created. Consequently, fan brake horsepower reductions cannot be read directly from the fan curve in inlet vane applications. Variable Frequency Drives Variable frequency drives provide the most efficient means of variable volume control by taking advantage of the fan law relation between fan speed (rpm) and fan brake horsepower (bhp). Also, since airflow reduction is accomplished by changing fan speed, the noise penalties often associated with mechanical control devices, e.g. inlet vanes, are not introduced. The following equation illustrates how fan bhp varies as the cube of the change in fan speed: density 2 hp 2 hp density 1 rpm = rpm 1 In an ideal system, at 50% fan speed, brake horsepower would be reduced to 12.5% of that at full speed. Variable frequency control varies the speed of the fan by adjusting the frequency and voltage to the motor. Keeping a constant volts/frequency ratio (constant magnetic flux) to the motor allows the motor to run at its peak efficiency over a wide range of speeds and resulting fan airflow volumes. Figure 4 on page 12 illustrates on a fan curve the effect of varying air volume with a variable frequency drive. Cat

12 Figure 4: Variable Frequency Drive Control 1. Higher operating efficiencies than commonly used forward curved fans, reducing system energy demands. 2. Higher operating efficiencies than commonly used forward curved fans, reducing electrical requirements. 3. A non-overloading brake horsepower curve. 4. A single wheel design, eliminating potential problems with fan paralleling at light loads. Airfoil Fans To further enhance VAV system performance, McQuay RoofPak VAV systems use efficient airfoil fan selections. McQuay airfoil fan selections feature: MicroTech II VAV Fan Tracking Control A key element in successful VAV application is the ability to track supply and return air fan volumes so that proper building static pressure is maintained. McQuay International, a pioneer in the development of rooftop VAV systems, developed its exclusive VaneTrol fan tracking control logic to solve just this issue. Incorporating over 30 years of rooftop VAV system experience, the latest generation MicroTech II controls with VaneTrol logic provide advanced and accurate duct static pressure control plus supply and return fan tracking control that effectively and efficiently manages building static pressure. The MicroTech II controller provides complete control of your variable inlet vane or variable frequency drive applications. For further information on this control, See MicroTech II Unit Controls on page Cat 214-5

13 MicroTech II Unit Controls Designed with the system operator in mind, McQuay RoofPak systems continue to provide industry leading performance, featuring the microprocessor based Micro- Tech II Applied Rooftop Unit Control system. The latest in microprocessor technology and software innovation have been used in each MicroTech II controller to give you the ultimate in rooftop control and flexibility. In addition to providing stable, efficient temperature and static pressure control, the controller is capable of providing comprehensive diagnostics, alarm monitoring and alarm specific component shutdown if critical equipment conditions occur. A user interface featuring an 8-key keypad and a 4-line x 20 character display, comes as standard with each Micro- Tech II control system, providing system operators with superior access to temperatures, pressures, operating states, alarm messages, set points, control parameters and schedules. All messages are displayed in plain English text. This high degree of system interface and diagnostics capability makes MicroTech II controls a recognized standard for total performance. Password protection is included to protect against unauthorized or accidental set point or parameter changes. The MicroTech II Applied Rooftop Unit Control system is capable of complete, stand-alone rooftop unit control. If desired, it can also provide interoperability with building automation systems (BAS) through McQuay s innovative Protocol Selectability. Protocol Selectability allows the unit control system to be factory or field configured for BACnet MS/TP, BACnet/IP or LonMark protocols. In addition, MicroTech II unit controls can be accessed via modem using a standard MicroTech II service tool. MicroTech II controls with Protocol Selectability provide more energy saving, comfort, indoor air quality, and operation management features than can be found in any other standard microprocessor-based system on the market today. Protocol Selectability MicroTech II unit control systems are factory configured for either standalone operation or for incorporation into independent building automation systems (BAS) through Protocol Selectability. By using industry recognized communication protocols, BACnet MS/TP, BACnet / IP or LonMark, McQuay MicroTech II controls expand the horizon of opportunities for BAS choice without the sacrifice of system performance. The same extensive range of functionality is available to the user if they use the independent BAS supplier of their choice as if they were to use a McQuay control network. BACnet communications conform to the BACnet Standard, ANSI/ASHRAE Standard , and are supported by a protocol implementation conformance statement (PICS). LonMark communications are in accordance with either the Discharge Air Controller (DAC) or Space Comfort Controller (SCC) profiles and are LonMark certified. The building automation system can interact with one or multiple rooftop unit controllers in the following ways: Set the unit s operating and occupancy modes Monitor all controller inputs, outputs, set points, parameters, and alarms Set controller set points and parameters Clear alarms Reset the cooling discharge air temperature set point (VAV and CAV-DTC units) Reset the heating discharge air temperature set point (VAV and CAV-DTC units with modulating heat) Reset the duct static pressure set point (VAV units) Set the heat/cool changeover temperature (VAV and CAV-DTC units) Set the representative zone temperature (CAV-ZTC units) Provide common fan control for multiple units on a common duct system. Components Each RoofPak applied rooftop system is equipped with a complete MicroTech II unit control system that is pre-engineered, preprogrammed, and factory tested prior to shipment. Each MicroTech II unit control system is composed of several components that are individually replaceable for ease of service. These components include: Keypad/display user interface Main control board Cooling control boards Electric heat control board (optional) Communication protocol module (optional) Pressure transducers Unit mounted temperature sensors Zone temperature sensor packages Main Control Board (MCB) The main control board (MCB) contains a microprocessor that is preprogrammed with the software necessary to control the unit. This can keep schedules, set points and parameters from being lost, even during a long-term power outage. The microprocessor board processes system input data and then determines and controls output responses. An RS-232 communication port is provided as standard to allow for direct or modem access with a PC based service tool. Cooling Control Boards (CCB1, CCB2) A cooling control board (CCB) is used on each refrigeration circuit to expand the input and output capability of the main control board (MCB). Each CCB communicates with the MCB via serial data communications. These microprocessor based boards provide independent operation and alarm response even if communication is lost with the MCB. Electric Heat Control Board (EHB1) An electric heat control board (EHB1) is used to expand the input and output capability of the main control board (MCB) whenever multi-stage electric heat is used. The EHB1 communicates with the MCB via serial data communications. This microprocessor based board provides independent operation and alarm response even if communication is lost with the MCB. Cat

14 Communication Protocol Module (CPM) The communication protocol module (CPM) provides the means to factory or field configure MicroTech II unit controls for interoperability with an independent BAS using McQuay s innovative Protocol Selectability. Communication protocol modules are available to support industry recognized communication protocols including BACnet MS/TP, BACnet / IP and LonMark. Keypad/Display All MicroTech II RoofPak controls include a keypad/display that provides user interface with the main control board (MCB). The keypad/display has eight easy-to-use, touch-sensitive membrane key switches that are used for positioning the display and entering changes. The display is a supertwist nematic type with highly visible black characters on a yellow background. The 4-line by 20-character format allows for easy to understand plain English display messages. All operating conditions, system alarms, control parameters and schedules can be monitored from the keypad/display. If the correct password has been entered, any adjustable parameter or schedule can be modified from the keypad. MicroTech II Keypad/Display Temperature and Humidity Sensors With the exception of the zone sensor, all temperature sensors are factory installed and tested. Zone sensor packages are available to suit any application. When required for dehumidification applications, a humidity sensor is available for field installation. Static Pressure Transducers All pressure transducers are factory installed and tested. Connection and routing of sampling tubes is done at time of unit installation. Zone Temperature Sensors Two optional zone temperature sensors are available: 1. Zone sensor with tenant override switch. 2. Zone sensor with tenant override switch and remote set point adjustment. Timed tenant override is a standard MicroTech II control feature. Zone sensors are required to utilize the controller s purge cycle, space reset of supply air set point, and night setback or setup features. All zone sensors are field installed with field wiring terminated at a separate, clearly marked terminal strip. Stand-alone Controller Features MicroTech II applied rooftop unit controls include all of the essential features required to make them capable of completely independent, stand-alone operation. Additional multiple unit control capabilities are available through optional MicroTech II system products or through control provided by a BAS. Internal Time Clock An internal, battery-backed time clock is included in the MicroTech II unit controller. Current date and time can be quickly and easily set at the user interface keypad. Internal Schedule Seven daily schedules and one holiday schedule can be entered at the keypad of all unit controllers. For each of these eight schedules, one start and one stop time can be entered. Up to 16 holiday periods, of any duration, can be designated. The unit will automatically run according to the holiday schedule on the holiday dates. To handle special occasions, an additional one event schedule can also be used. In lieu of its internal schedule, the unit can be operated according to a network schedule from a BAS. External Time Clock or Tenant Override Input An input is supplied that can be used to accept a field wired start/stop signal from a remote source. An external time clock, a tenant override switch, or both may be connected. Whenever the external circuit is closed, the controller overrides the internal schedule (if activated) and places the unit into the occupied mode. If the internal schedule or a BAS network schedule is used, field wiring is not required. Timed Tenant Override Off-hour operation flexibility is a must in today s office environments and even stand-alone MicroTech II controls handle it with ease. When unit operation is desired during unoccupied hours, timed tenant override can be initiated by pressing the tenant override button on either of the optional zone sensor packages. The unit will then start and run in the occupied mode for a keypad adjustable length of time (up to five hours). If the button is pressed again while the unit is operating, the timer will reset to the full time allowance without interrupting unit operation. Tenant override operation can also be initiated by a BAS. Remote Set Point Adjustment All constant air volume-zone temperature control (CAV- ZTC) unit controllers include an input that can be used to remotely adjust the zone cooling and heating set points. To utilize this feature, the optional zone sensor package 14 Cat 214-5

15 with set point adjustment must be wired to the controller. The remote set point adjustment feature can be enabled or disabled from the keypad at any time. When enabled, remote set point adjustment is available even if the return temperature is selected to be the Control Temperature. Auto/manual operation selection Automatic or manual operation can be controlled either remotely or at the keypad. All controllers include two inputs that can be used to enable or disable cooling, heating, and fan operation from remote switches. With the heat enable and cool enable terminals, the operator can enable cooling, heating, or both as desired. Using the system off terminals, the operator can disable the fans, and thus the entire unit, without the unit being able to be started remotely. From the keypad, there are a variety of occupancy and auto/manual control mode selections available to the operator: Occupancy modes Auto Occupied Unoccupied Bypass (tenant override) Control modes Off manual Auto Heat/cool Cool only Heat only Fan only Compressor Lead-lag Selection All unit controllers are capable of automatic compressor, lead-lag control. If automatic control is not desired, the operator can assign fixed lead and lag designations to the compressor circuits. Compressor Sequencing Selection Because all applications are not the same, MicroTech II controls provide two choices for compressor capacity staging. For high sensible demand, comfort cooling applications, cross-circuit unloading can be chosen to maximize part load efficiency. Cross circuit unloading takes maximum advantage of available condenser and evaporator surface areas. Lead-loading can be selected whenever part load dehumidification capability is of primary importance. Economizer Changeover Selection On units equipped with an economizer, there are three methods of determining whether the outdoor air is suitable for free cooling: two methods sense enthalpy (dry bulb temperature and humidity) and one senses outdoor air dry bulb temperature. The two enthalpy changeover methods use external, factory installed controls. One compares the outdoor ambient enthalpy to a set point; the other is a solid state device that compares the outdoor ambient enthalpy to the return air enthalpy. This comparative enthalpy control can improve total economizer performance. All unit controls include an internal dry bulb changeover strategy that can be selected at the keypad. When this method is selected, the controller compares the outdoor air dry-bulb temperature to a keypad programmable set point. The external enthalpy control input is then ignored. Cooling and Heating Lockout Control All unit controls include separate keypad programmable set points for locking out mechanical cooling and heating. Mechanical cooling is locked out when the outdoor temperature is below the cooling lockout set point; heating is locked out when the outdoor temperature is above the heating lockout set point. This feature can save energy cost by eliminating unnecessary heating and cooling during warm-up or cool-down periods or when the outdoor air temperature is mild. Night Setback and Setup Control When one of the zone temperature sensors is connected to the unit controller, night setback heating and night setup cooling control are available. Separate, keypad programmable night heating and cooling set points are used to start the unit when necessary. After the unit starts, night setback and setup control is similar to normal occupied control except that the minimum outside air damper position is set to zero. If the outside air is suitable for free cooling, it will be used during night setup operation. Except for 100% outside air applications, night setback control is available even if the unit is not equipped with any heating equipment. When the space temperature falls to the night setback set point, the fans simply start and run until the temperature rises above the differential. This feature might be useful for applications that utilize, for example, duct mounted reheat coils. Morning Warm-up Control If the space temperature is below set point when the unit enters the occupied mode, the morning warm-up control function will keep the outside air dampers closed while heat is supplied to satisfy set point. The outside air damper will remain closed until either the space temperature rises to the heating set point or the keypad adjustable morning warm-up timer expires (default is 90 minutes). The morning warm-up timer supplies the minimum required amount of outdoor air after a certain time regardless of the space temperature. Morning warm-up control is automatically included on all except 100% outside air units. It is available even if the unit is not equipped with any heating equipment, for applications that utilize, for example, duct mounted reheat coils. Outdoor Air Purge Control Designed to take advantage of cool early morning outside air conditions, purge control will start the fans and modulate the economizer dampers to maintain occupied cooling requirements during unoccupied periods if conditions are appropriate. This provides the opportunity to flush the space with fresh outdoor air prior to occupancy. Purge operation is possible only during a keypad adjustable time window prior to occupancy (0 to 240 minutes). When the purge-cycle is active, mechanical cooling is disabled. To utilize the purge feature, one of the zone temperature sensors must be connected to the unit controller. Following is a description of purge control operation. Cat

16 During the purge time window, the unit will start and run whenever these three requirements are met: The space temperature must be warm enough to enable occupied cooling. The outside air enthalpy must be low enough to enable the economizer. The outside air temperature must be at least 4 F less than the space temperature. When any one of these conditions is no longer true, the unit will be shut down again. As conditions allow, purge cycles the unit in this manner until it enters the occupied mode. Proportional Integral Derivative (PID) Control The Proportional-Integral-Derivative (PID) control algorithm controls modulating actuators to maintain a measured variable (temperature or pressure) at or near its set point. For example, it controls economizer dampers to maintain the discharge cooling set point and it controls the supply fan variable frequency drives to maintain the duct static pressure set point. The integral control feature effectively eliminates proportional droop (load dependent offset) resulting in the tightest possible control. For each PID loop, five keypad adjustable parameters allow the control loop to be properly tuned for any application: (1) period, (2) dead band, (3) proportional band, (4) integral time and (5) derivative time. Appropriate default values for these parameters are loaded into each controller. These default values will provide proper control for most applications; therefore, field tuning is usually not required and thus start-up time is reduced. Change Algorithm The PID function is also used to adjust set points instead of controlling variable speed drives or actuators directly. For example, in zone control applications, the PID loop automatically changes the discharge temperature set point (cooling or heating) as the Control Temperature deviates from the zone set point. Another PID loop then controls the economizer actuator or heating valve actuator using the current discharge temperature set point. Unlike a typical master-submaster reset strategy, this cascade control continuously adjusts the discharge set point, even if the Control Temperature s deviation from set point remains constant. This means that the unit s cooling or heating output is set according to the actual load, not just the current zone temperature. The tightest possible zone temperature control results because proportional droop (load dependent offset) is eliminated. Calibrate When initiated at the keypad by an operator, the Calibrate function automatically calibrates all actuator position feedback inputs and all pressure transducer inputs. It does this by shutting the unit down and then driving all actuators to the full closed and full open positions. The controller records the input voltage values that correspond to these positions. The pressure transducer input voltages, which are assumed for 0.00 in. W.C., are also recorded. When Calibrate is finished, an operator command must be entered at the keypad to start the unit. The Calibrate feature can reduce start-up time and assist in periodic maintenance. Field Output Signals All MicroTech II RoofPak controls include two solid-state relay outputs that are available for field connection to any suitable device: the remote alarm output and the occupied output. On VAV units, an additional VAV box output is available. These three outputs are used to signal field equipment of unit status. Remote Alarm Output: The remote alarm output can be used to operate a 24V relay to provide a remote alarm signal to a light, audible alarm, or other device when an alarm condition exists at the unit. Fan Operation Output: The fan operation output is used to control field equipment that depends on fan operation; for instance, to open field installed isolation dampers or VAV boxes. To allow actuators enough time to stroke, the fan operation output is energized three minutes before the fans start. It then remains energized until thirty seconds after the unit airflow switch senses no airflow. The fan operation output is on whenever the unit airflow switch senses airflow. VAV Box Output: The VAV box output provides a means of interfacing unit and VAV box control. When the output is energized (closed), the VAV output indicates that the unit is in the cooling mode. When de-energized (open), it indicates that the unit is either providing heat or circulating air to equalize temperature conditions just after start-up (this is the Recirculate operating state). On units with singlestage morning warm-up heat, the open VAV box output contact is meant to provide a signal to drive the boxes wide open. To prevent duct over pressurization, fan variable speed drives or inlet vanes are driven to a minimum position before the output s contacts are de-energized again for normal cooling operation (this is the Post Heat operating state). Standard Control Options Model RPS and RFS applied rooftop systems are available for most any constant or variable air volume application. MicroTech II controls offer three basic control configurations: variable air volume with discharge temperature control (VAV-DTC), constant air volume with zone temperature control (CAV-ZTC), and constant air volume with discharge temperature control (CAV-DTC), that use sophisticated state change control logic to provide stable, reliable and efficient control. When combined with Micro- Tech II s many available control capabilities, both factory installed and keypad programmable, these three basic configurations can be customized to meet the requirements of the most demanding applications. Variable Air Volume with Discharge Temperature Control (VAV) All VAV units provide true discharge temperature control in addition to duct static pressure control. Cooling only, cooling with single-stage morning warm-up heat, and cooling with modulating heat configurations are available. On units with a return fan, two building static pressure control options are available: VaneTrol logic tracking or direct building pressure control. Because proper ventilation rates have been identified as critical to maintaining good 16 Cat 214-5

17 indoor air quality, all RoofPak VAV controllers include software algorithms designed to maintain minimum outside air volume at all times when the unit is in the Occupied mode. Constant Air Volume with Zone Temperature Control (CAV-ZTC) CAV-ZTC units are available in either cooling only or cooling with modulating heat configurations. Either of these configurations is available for 100% recirculated, mixed, or 100% outdoor air applications. On units that have a return fan, a direct building static pressure control option is also available. Figure 5: Control Temperature: Discharge Temperature Control Constant Air Volume with Discharge Temperature Control (CAV-DTC) CAV-DTC units are available in cooling only, cooling with single-stage morning warm-up heat, or cooling with modulating heat configurations. This unit configuration can be used for applications that have zone controlled terminal reheat coils or for constant volume, 100% outdoor air applications. The discharge temperature control strategies used with the hybrid CAV-DTC unit are identical to those used with the VAV-DTC unit. On units that have a return fan, a direct building static pressure control option is available (constant supply air volume applications only). Discharge Temperature Control MicroTech II VAV-DTC and CAV-DTC controls provide sophisticated and flexible discharge air temperature control that is only possible with DDC systems. Separate discharge air temperature set points are used for cooling and modulating heating control. At the keypad, the operator can either enter the desired set points or select separate reset methods and parameters for each set point (see Supply Air Reset on page 17). Control Temperature The Control Temperature makes the heat/cool changeover decision. It determines whether cooling or heating is enabled; the discharge temperature then determines whether cooling or heating is actually supplied. At the keypad, the operator can choose the source of the Control Temperature from among the following selections. Space temperature sensor Return temperature sensor Outside air temperature sensor (modulating heat only) Network communication The operator enters separate cool and heat enable set points and deadbands that the Control Temperature is compared with (see Figure 5). When the Control Temperature is greater than or equal to the cooling set point, cooling is enabled. When the Control Temperature is less than or equal to the heat set point, heating is enabled. If desired, these set points and differentials can be set so that there is a dead band in which both cooling and heating are disabled. The controller s software prevents simultaneous cooling and heating. Proportional Integral Derivative Modulation When operating in economizer free cooling or unit heating, the previously described PID algorithm maintains discharge temperature control. The PID algorithm provides precise control of the economizer dampers, modulating gas heat, steam or hot water valves. Compressor Staging Two staging algorithms are available to control a unit s multiple steps of capacity control, Degree-Time and Nearest. These control algorithms provide reliable discharge temperature control while managing compressor cycling rates. Constraints on compressor staging are essential for preventing the short cycling which can reduce compressor life by causing improper oil return and excessive heat buildup in the motor windings. The Degree-Time Compressor staging algorithm keeps track of the discharge temperature and stages cooling up or down to maintain an average temperature that is equal to the discharge cooling set point. A stage change can only occur (1) after the keypad adjustable inter-stage timer has expired (five minute default setting) and (2) if the discharge temperature is outside a keypad programmed dead band. After these two conditions have been met, staging occurs as the controller attempts to equalize two running totals: degree-time above set point and degreetime below set point. The result is that the average discharge temperature is maintained at the cooling set point. The Nearest Compressor staging algorithm keeps track of the discharge temperature and stages cooling up or down to maintain the discharge temperature as close as possible to set point. A stage change can only occur (1) after the keypad adjustable inter-stage timer has expired (five minute default setting) and (2) if the control logic calculates that a stage change will result in a discharge temperature closer to set point than the existing condition. The controller logic continually calculates the expected effect of a stage change and uses this information before making a change. A change is made only if it will bring the discharge temperature closer to set point, resulting in a more consistent discharge temperature, reduced compressor cycling and more stable control VAV box control. Supply Air Reset By automatically varying the discharge air temperature to suit a building s cooling or heating needs, supply air temperature reset can increase the energy efficiency of VAV Cat

18 and CAV-DTC systems. MicroTech II controllers offer a variety of different reset strategies that can be selected at the keypad. Because they are keypad programmable, reset strategies can be changed or eliminated as desired. Separate strategies can be selected for both cooling and modulating heat. If reset is not desired, a fixed discharge cooling or heating set point can be entered. The following reset methods are available: Space temperature Return temperature Outdoor air temperature Supply airflow (VAV, cooling set point only) External 1-5 VDC or 4-20mA signal Network communication For all temperature reset methods, the minimum and maximum cooling and heating set points are keypad programmable along with the corresponding minimum and maximum space, return or outdoor air temperature parameters. For the supply airflow method, the discharge set point will be reset as the supply fan modulates between 30% and 100%. For the external method, the discharge set point will be reset as the voltage or current signal varies over its entire range. For units in a BAS network, the discharge set points are reset via the communication signal. Multiple Unit Applications Common heat/cool changeover control for multiple unit applications is available with optional MicroTech II system products. Zone Temperature Control MicroTech II CAV-ZTC controls provide the sophisticated and flexible zone temperature control that is only possible with DDC systems. Zone temperature sensors are available with or without a remote set point adjustment. With the remote adjustment model, the space set point can be set at the keypad or at the zone sensor package. (Even if a zone sensor is connected, remote set point adjustment can be enabled or disabled as desired at the keypad.) Control Temperature The Control Temperature is the representative zone temperature. When compared with the zone set points, the Control Temperature determines whether the unit supplies heating, cooling, or neither. It also determines the amount of cooling or heating required to satisfy the load. Its source can be selected at the keypad from among the following selections: Zone temperature sensor Return temperature sensor Because it is the representative zone temperature, the Control Temperature is the primary input to the MicroTech II zone temperature control algorithms. Control Temperature parameters are described below. The controller s software will prevent cooling and heating from being inadvertently enabled at the same time. Change and Proportional Integral Derivative Modulation When economizer free cooling or unit heating is required, the two MicroTech II PID loops combine for cascade-type control, providing the tightest possible zone temperature control. By controlling the discharge temperature along with the zone temperature, these functions eliminate temperature variations near the diffusers that could otherwise occur as a result of traditional zone control s inherent lag effect. Change: If the Control Temperature is above or below the set point by more than the dead band, the Change PID loop periodically adjusts the cooling or heating discharge air temperature set point either up or down as necessary. The amount of this set point change corresponds to the Control Temperature s position in the modulation range. The farther the Control Temperature is from the set point, the greater the discharge set point change will be. The Change-adjusted discharge cooling and heating set points are limited to ranges defined by keypad programmable maximum and minimum values. PID: Using the Change function s current discharge set point, the PID function maintains precise discharge temperature control by modulating the economizer dampers and gas heat, steam or hot water heating valves. Compressor Staging Compressor staging is controlled directly by the Control Temperature. When the Control Temperature is warmer than the zone cooling set point, cooling is staged up; when the Control Temperature is cooler than the zone cooling set point, cooling is staged down. However, a stage change can only occur when the Control Temperature is outside the dead band (see Figure 6). Staging is constrained by an inter-stage delay timer (five minute default setting) and minimum and maximum discharge air temperature limits (all keypad programmable). These constraints protect the compressors from short cycling while eliminating temperature variations near the diffusers. Figure 6: Compressorized Discharge Temperature Cooling Project Ahead Algorithm Because the inherent lag effect in zone temperature control applications can cause overshoot during warm-up or cool-down periods, MicroTech II features a unique Project Ahead control algorithm. Project Ahead calculates the rate at which the Control Temperature is changing and reduces the unit s cooling or heating output as the zone temperature nears its set point, essentially eliminating overshoot. A separate, keypad programmable Project Ahead time parameter for both heating and cooling allows for control fine tuning. Duct Static Pressure Control On all VAV-DTC units, duct static pressure control is maintained by the PID algorithm, which provides precise control of the supply fan variable speed drive or inlet vanes. 18 Cat 214-5

19 The keypad programmable set point can be set between 0.20 in. W.C. and 4.00 in. W.C. On larger buildings with multiple floors, multiple trunk runs or large shifts in load due to solar effects (East/West building orientation), an optional second duct static sensor is offered. The MicroTech II controller will automatically select and use the lower of the two sensed pressures to control fan volume to provide adequate static pressure to the most demanding space at all times. Multiple Unit Applications For applications in which multiple units are connected in a common duct system, it is important to control all units from a common duct static pressure sensor and to control all operating units in unison. Centralized duct static pressure control is available through optional MicroTech II system products or through control provided by a BAS. Building Static Pressure Control VaneTrol Fan Tracking Control (Does Not Apply to Exhaust Fans) VaneTrol fan tracking control logic offers close and reliable building static pressure control for VAV units equipped with a return air fan. With the VaneTrol logic method, the return fan s variable speed drive or inlet vane assembly tracks the supply fan volume as the supply fan maintains the required duct static pressure using the additional parameter of maintaining a field programmable offset between supply fan and return fan volume. The result is that building pressure is maintained, regardless of the building cooling load, because the proper relationship between supply and return fan volume is maintained. Because the return fan/supply fan tracking relationship is established once during controlled test and balance conditions, ongoing building pressure control is not affected by a fluctuating ambient pressure reference signal or the temporary effects of opening and closing doors on a pressure sensor in the lobby. VaneTrol control logic uses four keypad programmable parameters to maintain the required relationship between return fan and supply fan volumes. These are the supply and corresponding return fan volumes as measured by inlet vane or variable speed drive position, at both maximum and minimum airflow conditions. If the building includes an additional, remote intermittent exhaust fan(s) that will affect building pressure when energized, the VaneTrol logic provides the capability to compensate for it through the use of a second set of inputs. Table 2 shows an example of how supply and return air fan modulation must vary to maintain the correct balance of supply and return air volumes based on the building s parameters, and therefore maintain building pressure. MicroTech II makes determining the building s correct VaneTrol parameters easy with its Balance feature. With Balance, start-up time is reduced because final adjustments are made at the keypad. Table 2: VaneTrol Logic Air Balancing SAF CFM RAF CFM Building Exhaust Remote Exhaust Off Remote Exhaust On Remote Exhaust Off Remote Exhaust On (100%) (100%) (93%) (88%) (%) (79%) (%) (71%) 9000 (64%) (63%) 00 (57%) 7000 (50%) (50%) 6000 (43%) 5000 (36%) Direct Space Pressure Control (For Return or Exhaust Fans) Any constant or variable air volume unit equipped with a variable volume return or exhaust fan can be provided with direct building static pressure control capability. With the direct method, building static pressure is measured and processed by the PID algorithm. This algorithm provides precise control of the return fan variable speed drive or inlet vanes to maintain the space pressure set point. The range of the keypad programmable set point is between minus 0.25 in. W.C. and 0.25 in. W.C. This type of control can be used for either whole building or lab pressurization (positive or negative) applications, or exhaust fan control, where VaneTrol control logic does not apply. Minimum Ventilation Air Volume Control Consistently maintaining the minimum outdoor air requirements of ASHRAE Standard has been a long standing control challenge for VAV systems. As supply air fan volumes were reduced, the volume of air introduced through a fixed position, minimum outdoor air damper was also reduced, compromising indoor air quality. To meet this challenge, MicroTech II controls feature three user selected control methods for maintaining outdoor air volume. 1. The MicroTech II controller can accept a signal from a DesignFlow Precision Outdoor Air Control system, that is continuously measuring outdoor air volume, and adjust outdoor air damper position to maintain the minimum volume set point. 2. MicroTech II controls have a keypad selected control function that automatically adjusts outdoor air damper position in response to changes in supply air fan volume. Regardless of supply air volume, this strategy maintains a nearly constant outdoor air volume at all times. 3. The MicroTech II controller can accept an external 1-5 VDC signal from a CO2 sensor or other control device and adjust outdoor air damper position. Cat

20 4. If desired, a fixed minimum damper position can be keypad programmed. This selection may be acceptable when ventilation requirements are met through other sources. During cold ambient conditions where outdoor/return mixed air conditions can become too low, MicroTech II controls will maintain the cooling discharge temperature set point by controlling the unit heating system. For applications in which ambient temperatures and minimum outdoor air requirements can generate this condition, the RoofPak unit should be ordered with modulating heating equipment, such as the SuperMod gas burner. Table 3 illustrates the effect of minimum ventilation control and cold ambient conditions on unit discharge air temperature and how it dictates the need for mixed air tempering capability at the light load/low ambient conditions. It assumes a VAV unit with a 20% outdoor air requirement at design conditions and a 40% minimum airflow requirement. Table 3: Effect of Minimum Ventilation Control on Discharge Temperature Supply Fan Volume (cfm) Outdoor Air Volume (cfm) Operating States Outdoor Air Volume (%) Outdoor Air Temp. ( F) Mixed Air Temp. ( F) 10,000 2, ,000 2, ,000 2, ,000 2, Operating states define the current overall status of the rooftop system. At the user interface, the operator can display the current operating state and thereby quickly assess the unit s operating condition. Figure 7 shows all possible operating states and the status information they summarize. Depending on unit options, some operating states may not apply. For example, a 100% outside air unit will not have a Morning Warm-Up, Economizer or Unoccupied Economizer operating state. Following are descriptions of each operating state. Off There are five different Off operating states. In any Off operating state, the fans are off, the outdoor air dampers are closed, any variable speed drives or inlet vanes are driven to 0% and cooling and heating are disabled. The Fan Operation output is de-energized (open) and the VAV box output is energized (closed). The specific Off operating state displayed, provides the reason the unit is in Off. The five different Off operating states are: 1. Off - Alarm This state is displayed whenever an active alarm of the fault type has the unit shut down. 2. Off - Manual The unit is in the Off-Manual state whenever the Control Mode parameter is set to Off. Off - Network This state is displayed when the unit operating mode has been set to Off by a network communication signal. 3. Off - Unoccupied This state is displayed when the unit is being scheduled on and off by a time clock function and the schedule indicates an unoccupied period. 4. Off - Switch This state is displayed when the contacts of a field supplied enable switch are closed. Off states are prioritized as shown above, with Off-Alarm having the highest rank. If a unit is in the Off-Alarm state, the unit can not be started until the alarm is cleared. Figure 7: Operating State Sequence Chart ) O 5 J= JA BB 5 J= HJK F 4 A? EH? K = JA 7? + C + E C A = JE C 7? 0 JC 7? -? -? E A H = O E, ) 6 20 Cat 214-5

21 Startup Whenever a unit is commanded to start the control always enters the Startup operating state from the Off state. The unit remains in the Startup operating state for an adjustable time period (default set at 3 minutes) before entering the Recirculate state. During the Startup operating state the fans remain off, outdoor air dampers are driven closed, variable speed drives or inlet vanes are driven to their 0% or closed position, cooling and heating remain disabled, the Fan Operation Output is closed and the VAV Box output is open. The Startup operating state will help start fans unloaded while allowing airflow status to be proven quickly. Recirculate Units with return air always enter the Recirculate operating state after completion of the StartUp operating state. In the Recirculate state the fans are energized while the outdoor air dampers remain closed. This allows temperature conditions throughout the unit and space to equalize before temperature control begins. During the Recirculate operating state, cooling and heating are disabled, the outside air dampers are closed, the Fan Operation output is closed, the VAV box output is open, and the variable speed drives or inlet vanes are modulated to maintain the duct static pressure set point. The unit operates in the Recirculate operating state until a field set Recirculate State Time period (2 to 60 minutes) expires. Fan Only The Fan Only operating state occurs during occupied operation when cooling and heating are either not required or disabled. In the Fan Only operating state, the outside air dampers are at minimum position, and cooling and heating are disabled and the Fan Operation output is closed. The VAV box output may be closed or open depending on the time and the previous operating state. Post Heat Operation When a VAV unit enters the Fan Only operating state from Recirculate or any heating state, a special post heat mode of operation occurs. In VAV systems, the VAV boxes are typically forced to a wide-open position during operation in the Recirculate or any heating state, using the VAV Box output signal, to facilitate rapid heat transfer to the space. As a result, since the unit is being controlled to maintain duct static pressure, the discharge fan capacity will be at a maximum position. During post heat operation, normal duct static pressure control is overridden and the discharge fan variable speed drive or inlet vanes are forced to a minimum position while the VAV boxes remain open. This eliminates potential duct over-pressurization problems that can otherwise occur during the transition from heating to cooling operation when the VAV boxes regain zone temperature control. The VAV Box output is held in the open (heat) position for a time period set at the keypad or the supply fan variable speed drive drops below 25% (inlet vane position drops below 17%), at which time normal Fan Only operation occurs. Economizer In the Occupied mode, the unit enters the Economizer operating state when cooling is required and outdoor air enthalpy or dry bulb control indicates free cooling is available. During the Economizer operating state, mechanical cooling and heating are disabled. The economizer dampers are modulated to maintain the cooling discharge temperature set point. The Fan Operation output is closed and the VAV Box output is closed (cool). When conditions are such that the outside air is unable to satisfy the cooling load, the transition from the Economizer state to the Cooling operating state occurs. Cooling In the Occupied mode, the unit enters the Cooling operating state when cooling is required and the economizer is either fully open or disabled. Mechanical cooling is supplied as required to maintain the Occupied discharge temperature cooling set point. The Fan Operation output is closed, the VAV Box output is closed (cool) and heating is disabled. Morning Warm-Up The unit enters the Morning Warm-Up (MWU) operating state when the unit transitions from unoccupied to occupied and when heating is required to bring the Control Temperature up to the occupied heating set point. The unit may go into MWU even when no heating resides in the unit. The MWU operating state is similar to Heating with the difference being that the outside air dampers are held shut rather than at minimum position. The control will remain in the MWU state until either the Control Temperature rises to the occupied heating set point or until the Maximum MWU timer expires. The Fan Operation output is closed, the VAV Box output is open (heat), cooling is disabled and the fan is controlled to maintain normal duct static pressure. Heating The Heating operating state is entered when heating is required during Occupied operation to maintain the Control Temperature above the heating set point. During the Heating operating state, the outdoor air dampers are maintained at minimum position. The Fan Operation output is closed, the VAV Box output is open (heat), cooling is disabled and the fan is controlled to maintain normal duct static pressure. Minimum Discharge Air Temperature The unit enters the Minimum Discharge Air Temperature (DAT) state during Occupied operation when the Control Temperature indicates that neither cooling or heating is required but the discharge temperature falls below the discharge temperature cooling set point. The Minimum DAT state prevents cold discharge air temperatures during what would normally be Fan Only operation. During the Minimum DAT state, the outdoor air dampers are maintained at minimum position and cooling is disabled. The Fan Operation output is closed and VAV Box output is closed (cool). Unoccupied Economizer If outdoor air is suitable for free cooling when purge or night setup operation is required, the unit will operate in the Unoccupied Economizer operating state. During Unoccupied Economizer, the outdoor air dampers are modulated to maintain the discharge temperature cooling set point, heat- Cat

22 ing is disabled and fan volume is controlled to maintain normal duct static pressure. The Fan Operation output is closed and the VAV Box output is closed (cool). For night setup operation, the transition from Unoccupied Economizer to Unoccupied Cooling is similar to the occupied transition described in Economizer. For purge operation, mechanical cooling is disabled. Unoccupied Cooling The unit enters the Unoccupied Cooling state when night setup operation is required and outdoor air conditions are not suitable for free cooling or cannot satisfy the unoccupied cooling set point. During Unoccupied Cooling, outdoor air dampers are either in the 100% open position for free cooling or closed, fan volume is controlled to maintain normal duct static pressure and heating is disabled. The Fan Operation output is closed and VAV Box output is closed (cool). Unoccupied Heating The unit enters the Unoccupied Heating state when night setback operation is required. During Unoccupied Heating, outdoor air dampers are closed, fan volume is controlled to maintain normal duct static pressure and cooling is disabled. The Fan Operation output is closed and the VAV Box output is open (heat). Alarm Management and Control MicroTech II unit controllers are capable of sophisticated alarm management and controlled response functions. Each alarm is prioritized, indicated, and responded to with the appropriate action. The current alarm (up to four alarms, arranged by alarm priority) and previous alarm (up to eight alarms, arrange by date/time cleared), each with a time and date stamp, can be displayed at the user interface. Whenever a current alarm is cleared, it is logged as a previous alarm and the current alarm becomes the new previous alarm, and the oldest previous alarm is removed. Alarm Priority The various alarms that can occur are prioritized according to the severity of the problem. Three alarm categories are used: faults, problems, and warnings. 1. Faults are the highest priority alarms. If a fault condition occurs, the complete unit will be shut down until the alarm condition is gone and the fault has been manually cleared at the keypad. A fault example would be Fan Fail alarm. 2. Problems are the next lower priority to faults. If a problem occurs, the complete unit will not be shut down, but its operation will be modified to compensate for the alarm condition. A problem will automatically clear when the alarm condition that caused it is gone. Compressor Fail would be an example of a problem, where just the affected compressor is shut down. 3. Warnings are the lowest priority alarms. No control action is taken when a warning occurs; it is simply indicated to alert the operator that the alarm condition needs attention. To remind the operator to read warnings, they must be manually cleared. Dirty Filter indication would be an example of a warning. Generally, a specific alarm condition will generate an alarm that falls into only one of these categories. Under different sets of circumstances, however, the freezestat and most of the sensor failure alarm conditions can generate alarms that fall into multiple categories. Adjustable Alarm Limits Four alarm triggers have adjustable limits. The high return temperature alarm and the high and low supply temperature alarms are adjusted at the user interface. The dirty filter alarm(s) is adjusted at the sensing device. Table 4: MicroTech II Alarm Summary Alarm Name Fault Problem Warning Freeze X X Smoke X Temperature Sensor Fail X X Duct High Limit X High Return Temp X High Discharge Temp X Low Discharge Temp X Fan Fail X Fan Retry X Discharge Air Capacity Feedback X OA Damper Stuck X X Auxiliary Control Board Enable X Auxiliary Control Board Communications X Low Airflow X Heat Fail X Circuit 1 & 2 High Pressure X Circuit 1 & 2 Low Pressure X Circuit 1 & 2 Frost Protect X Compressor 1-4 Fail X Circuit 1 & 2 Incomplete Pumpdown X Auxiliary Control Board Enable Hardware X Airflow Switch (False Airflow) X Dirty Filter X Dirty Final Filter X MicroTech II System Products Multiple Unit Control Multiple RoofPak units in a common system can be controlled using MicroTech II system products. A MicroTech II network can be established to access and set all common control parameters, such as: Common duct static pressure control of multiple VAV units. Common heat/cool changeover control of multiple VAV or CAV-DTC units. Common zone temperature control of multiple CAV-ZTC units. Personal Computer Based Service Tool A personal computer (PC) can be equipped with Windows -based MicroTech II service tool software to provide a high-level operator interface with the MicroTech II unit controls for expanded diagnostic and service capability. The service tool can be connected directly to the MicroTech II controller, or used remotely with the addition of an optional unit mounted phone modem. 22 Cat 214-5

23 Application Considerations The following section contains basic application and installation guidelines that must be considered as part of the detailed analysis of any specific project. General Units are intended for use in normal heating, ventilating and air conditioning applications. Consult your local McQuay sales representative for applications involving operation at high ambient temperatures, high altitudes, non-cataloged voltages and for applications requiring modified or special control sequences. Consult your local McQuay sales representative for job specific unit selections that fall outside of the range of the catalog tables, such as 100% outside air applications. For proper operation, units should be rigged in accordance with instructions stated in IM 4. Fire dampers, if required, must be installed in the ductwork according to local or state codes. No space is allowed for these dampers in the unit. It is strongly recommended that factory check, test and start procedures be explicitly followed to achieve satisfactory start-up and operation (see IM 4). Most rooftop applications take advantage of the significant energy savings provided with economizer operation. When an economizer system is used, mechanical refrigeration is typically not required below an ambient temperature of 50 F. Standard RoofPak refrigeration systems are designed to operate in ambient temperatures down to 45 F. For applications where an economizer system cannot be used, McQuay s SpeedTrol head pressure control system is available on size 045C-135C units to permit operation down to 0 F. However, if the condenser coils are not properly shielded from the wind, the minimum ambient conditions stated above must be raised. Unit Location The structural engineer must verify that the roof has adequate strength and ability to minimize deflection. Take extreme caution when using a wooden roof structure. Locate the unit fresh air intakes away from building flue stacks or exhaust ventilators to reduce possible reintroduction of contaminated air to the system. Unit condenser coils should be located to avoid contact with any heated exhaust air. Allow sufficient space around the unit for maintenance/service clearance as well as to allow for full outside air intake, removal of exhaust air and for full condenser airflow. Refer to Recommended Clearances on page 100 for recommended clearances. Consult your McQuay sales representative if available clearances do not meet minimum recommendations. Where code considerations, such as the NEC, require extended clearances, they take precedence. In applications utilizing a future cooling unit (RFS), care should be taken in choosing a location of the unit so it will provide proper roof support and service and ventilation clearance necessary for the later addition of a mechanical cooling section (RCS). Split Units Units may sometimes have to be split into multiple pieces to accommodate shipping limitations or jobsite lifting limitations. Units exceeding 52 feet in length may need to be split for shipping purposes. Units exceeding the rating of an available crane or helicopter may also need to be split for rigging purposes. Unit can be split at the condensing section or split between the supply fan and heat section. Contact your local McQuay sales representative for more details. Curb Installation The roof curb is field assembled and must be installed level (within 1/16 in. per foot side to side). A sub-base has to be constructed by the contractor in applications involving pitched roofs. Gaskets are furnished and must be installed between the unit and curb. For proper installation, follow NRCA guidelines. Typical curb installation is illustrated in Roof Curbs on page 92. In applications requiring post and rail installation, an I-beam securely mounted on multiple posts should support the unit on each side. Applications in geographic areas that are subjected to seismic or hurricane conditions must meet code requirements for fastening the unit to the curb and the curb to the building structure. For acoustical considerations, the condensing section is provided with a support rail versus a full perimeter roof curb. When curbs are installed on a built-up roof with metal decking, an inverted 6 in. channel should be provided on both sides of the unit. Acoustical material should be installed over the decking, inside the roof curb. Only the supply and return air ducts should penetrate the acoustical material and decking. Appropriate acoustical and vibration design practices should be applied during the early stages of design to provide noise compatibility with the intended use of the space. Consult your McQuay sales representative for unit sound power data. Acoustical Considerations Good acoustical design is a critical part of any installation and should start at the earliest stages in the design process. Each of the four common sound paths for rooftop equipment must be addressed. These are: (1) radiated sound through the bottom of the unit bottom [air handling section and condensing section] and into the space, (2) structure borne vibration from the unit to the building, (3) airborne sound through the supply air duct and (4) airborne sound through the return air duct. Locating rooftop equipment away from sound sensitive areas is critical and the most cost effective means of avoiding sound problems. If possible, rooftop equipment should always be located over less sensitive areas such Cat

24 as corridors, toilet facilities or auxiliary spaces and away from office areas, conference rooms and classrooms. Some basic guidelines for good acoustical performance are: 1. Always provide proper structural support under all areas of the unit. 2. Always locate the unit s center of gravity close to a main support to minimize roof deflection. Maintaining a roof deflection under 1/3 in. will assist in minimizing vibration induced noise. 3. Use a concrete deck or pad when a unit has to be located over an occupied space where good acoustics are essential. 4. Only the supply and return air ducts should penetrate the acoustical material and decking within the curb perimeter, and the openings should be sealed once the duct is installed. 5. Don t overlook the return air path. Never leave a clear line of sight into a return or exhaust fan, always include some duct work (acoustically lined tee) at the return inlet. 6. Place an acoustical material in the area directly beneath the condensing section. 7. Minimize system static pressure losses to reduce fan sound generation. 8. Select the appropriate fan for the application. Fans should be selected as close as possible to their peak static efficiency. To assist you, peak static efficiency is identified by the first system curve to the right of the shaded Do not select region, as illustrated in Figure 8 on page Design duct systems to minimize turbulence. 10. Account for low frequency duct breakout in system design. Route the first 20 ft. of rectangular duct over non-sensitive areas and avoid large duct aspect ratios. Consider round or oval duct to reduce breakout. 11. When an added measure of airborne fan sound control is required, sound attenuators can be supplied, factory installed in a unit discharge air section, to treat the supply fan. On the return side, additional attenuation can often be achieved by routing the return duct within the curb area beneath the unit. Figure 8: Optimal Fan Selection Line There are many sound sources in rooftop systems. Fans, compressors, condenser fans, duct take-offs, etc. all generate sound. For guidelines on reducing sound generation in the duct system, refer to the 1995 ASHRAE Applications Handbook, Chapter 43. Contact your local McQuay sales representative for equipment supply, return and radiated sound power data specific to your application. Ductwork A well-designed duct system is required to allow the rooftop equipment to provide rated performance and to minimize system resistance and sound generation. Duct connections to and from units should allow straight, smooth airflow transitions. Avoid any abrupt change in duct size and sharp turns in the fan discharge. Avoid turns opposed to wheel rotation as they will generate air turbulence and result in unwanted sound. If 90 turns are necessary, turning vanes should be used. Refer to the 1995 ASHRAE Applications Handbook, Chapter 43 for specific guidelines relevant to rooftop equipment. Return Duct The return path is the most often overlooked. A section of return duct is required to avoid a line of sight to the return air opening and to provide attenuation of return air sound. Install an insulated tee with a maximum duct velocity of 1000 to 1200 feet per minute. Extend the duct 15 feet to provide adequate attenuation. Supply Duct Insulate supply air ductwork for at least the first 20 feet from the unit. Consider the use of round or oval ductwork, as it will significantly reduce low frequency breakout noise near the equipment. If rectangular duct is used, keep the 24 Cat 214-5

25 aspect ratio of the duct as low as possible. The large flat surfaces associated with high aspect ratios will increase low frequency breakout to the space and can generate noise, such as oil canning. The maximum recommended supply duct velocity is 10 to 2000 feet per minute. Duct High Limit All McQuay RoofPak systems with VAV control include an adjustable duct high limit switch as a standard feature. This is of particular importance when fast acting, normally closed boxes are used. The switch is field adjustable and must be set to meet the specific rating of the system ductwork. Vibration Isolation Make duct attachments to the unit with a flexible connection. Economizer, Return Fan and Exhaust Fan Application Maintaining proper building pressure of approximately to 0.1", or perhaps a neutral pressure in the winter, is very important: 1. Excessive space pressure can cause strong drafts when doors open, resulting in large fluctuations in the local zone pressure and poor zone temperature and supply air control. 2. Insufficient space pressure control can allow unconditioned air to infiltrate, resulting in poor perimeter temperature control, summer condensation in the walls, and excessive energy expenses. Powered return [RAF] or exhaust fans [EAFs] are often required to prevent excessively high building pressure on rooftop applications. This is illustrated in Figures 1 and 2. Figure 9: $ ) J5 ) K J A J Supply Air Fan Only System Static Pressures, Return duct ESP is 1.0" ' ) J5 ) 1 A J ) ' 1 4 BJ F -? E A H 5 A? JE - ) building pressure for the conditions listed in Figure 1assuming the wide open return damper APD is 0.2". Figure 10: Required Rooftop Unit Static Pressures, SAF Only, Return duct ESP is 1.0" ' ) J5 ) 1 A J $ ) J5 ) K J A J There are two reasons why building pressure or ventilation air control will suffer if no RAF or EAF is provided: 1. No exhaust will occur from the rooftop since the economizer section must be controlled to be at negative pressure. The building must naturally exhaust the minimum OA. This generally causes excessively positive building pressure. See Table 56 on page The air balancer must adjust the minimum OA dampers to bring in the right amount of OA, and also generate a relatively large OA damper APD of 1.1", in order to maintain the necessary economizer static pressure. This is not practical with conventional OA dampers: a. The required 1.1" pressure drop will only occur when the damper is virtually closed. b. Damper airflow is extremely volatile when the damper is virtually closed. Figure 11 illustrates how to add a RAF to Figure 10, obtain proper exhaust, and properly control design building pressure. The return fan always draws negative pressure at the unit's inlet to allow for the 1.0" return duct APD while maintaining a space pressure at the desired 0.1" ) J I F D A HE? 2 HA I I K HA ' 1 4 BJ F -? E A H 5 A? JE Figure 11: RAF System Pressures Allow proper Exhaust And Outdoor Air Control 4 ) ) J I F D A HE? 2 HA I I K HA # 5 K F F O JA H = 5 2?? K F 5 F =? A ) J 5 J= JE? 2 HA I I K HA 4 A JK H ' ) J5 ) 1 A J ) J4 ) K J A J ) J ) 1 A J Because air flows from higher to lower static pressure, if the space static pressure is 0.1", then the rooftop's economizer section static pressure must be -0.9" for the conditions listed in Figure 9. $ ) J5 ) K J A J ' ) J4 ) 1 A J Figure 10 details the static pressures that must exist in the mixing box of the rooftop unit in order to maintain proper EAF operation is quite different than RAF operation. First of all there are two modes of operation Cat

26 1. The EAF does not operate when the unit's economizer is at the minimum OA position, such as when the unit experiences design cooling capacity, or else operates at extremely light load. 2. An EAF only operates near full capacity during the economizer mode. Exhaust fans have trouble controlling building pressure and minimum OA in mode of operation #1, particularly when return ESP increases, as illustrated in Figures 1 and 2. Essentially, if the EAF is off, or barely operating, the system reacts like the previously discussed, SAF only system. 1. The unit's economizer section must be negative and no exhaust will occur if the fan is off. If the EAF is on, it will have difficulty exhausting the correct amount, because volume must generally be controlled between 5 and 15% of design airflow. 2. The OA dampers must generate a relatively large APD at minimum position in order to allow sufficient negative pressure in the unit's economizer section. Conventional minimum OA damper control is not accurate at these pressures. These problems diminish or disappear when return duct ESP is reduced to 0.4" as shown in Figure The unit's economizer section must only be slightly negative to allow proper building pressure. 2. The minimum OA damper APD need only be about 0.5" and conventional dampers generally provide satisfactory operation. 3. These problems are further reduced if an accurate minimum OA control damper, like McQuay's Design- Flow, is utilized. Figure 12: EAF system static pressures at 0.4" return ESP and minimum OA [EAF off]! ) J5 ) 1 A J $ ) J5 ) K J A J # ) J ) 1 A J ) J I F D A HE? 2 HA I I K HA! 1 4 BJ F -? E A H 5 A? JE! ) J- ) 1 A J The major advantage offered by EAFs is the opportunity to save energy. EAF systems often draw less energy than RAF systems, if equal fans are compared, for 2 reasons. 1. They operate at a relatively lighter load because properly controlled EAFs turn down in response to two criteria and RAFs turn down in response to just one. a. Both turn down equally in response to a reduction in SAF CFM on VAV systems. b. EAFs only operate at full CFM when the economizer is at 100% OA,and turn down as OA CFM drops, for both CV and VAV systems. 2. The SAF is generally operating at a more efficient point of operation [greater TSP] than either an EAF or RAF. Therefore turning off the EAF, and shifting return ESP to the SAF, generally takes less BHP than operating a system with a separate SAF and RAF. Conclusions are as follows: 1. A powered RAF or EAF is generally required to properly control building pressure and minimum OA intake whenever economizers are included on a rooftop unit unless provisions for remote exhaust are made. 2. Return fan and exhaust fan performance is not the same. Some applications are better suited for a return fan and others for an exhaust fan. a. Return fans are recommended when return duct ESP exceeds 0.8 due to their superior control on minimum outdoor air intake and building pressure. b. Exhaust fans are recommended when they save energy and when return duct ESP is less than 0.4. c. Either fan may be better suited when return duct ESP is between 0.4 and 0.8. However, they are not necessarily interchangeable in a given design. 3. RAFs are recommended when the return ESP exceeds 0.8", because of their superior control of minimum OA and building pressure, and because they are effective at any return duct APD. 4. EAFs are recommended whenever they save energy and return duct ESP is less than 0.4". 5. EAFs generally should not be used above 0.8" return ESP, therefore, propeller fans are utilized. Filters General Filters should be routinely replaced to minimize filter loading. As filters get dirty, the filter pressure drop increases, causing a decrease in airflow. Depending on fan type, forward curved or airfoil, this airflow change can be significant. The effect of filter loading is the most critical when using 65% and 95% efficient filters. When making a fan selection, a pressure drop component for filters as they get dirty should be included in the system total static pressure. A value midway between clean and dirty filter ratings is recommended. If a minimum airflow is critical, the fan selection should be made using the higher, dirty filter pressure drop value. Following these recommendations should limit airflow fluctuation as the filters load. Final Filters The application of final filters (filters downstream of the fan) places special requirements on unit selection. When final filters are employed, cooling coils must be located in the draw-through position so that the filters will not be in a saturated air stream. Also, final filters applications for a unit with gas heat requires the filters to be rated for 500 F. Instruct maintenance personnel to use properly rated replacement filters. 26 Cat 214-5

27 Variable Air Volume Application RoofPak units are available with variable inlet vanes or variable speed drives to provide variable air volume (VAV) control. Refer to Variable Air Volume on page 11 for further information on VAV systems. In placing a duct static pressure sensor, locate a pressure tap near the end of the main duct trunk. Adjust The static pressure setpoint so that at minimum airflow all of the terminals receive the minimum static pressure required plus any downstream resistance. Locate the static pressure sensor tap in the ductwork in an area free from turbulence effects and at least ten duct diameters downstream and several duct diameters upstream from any major interference, including branch takeoffs. A second sensor is available and should be used on installations having multiple duct trunks, multiple floors, or significantly varying zones (i.e., east/west). The MicroTech II controller will control the inlet vanes or variable speed drive to satisfy the supply duct requiring the most static pressure. On units with discharge air control, maximum compressor unloading and hot gas bypass is recommended. Fan Operating Range The acceptable system operating range of the McQuay rooftop is determined by all of the following characteristics. Each of these limiting factors must be considered for proper performance and component design life. 1. Unstable fan operation 2. Maximum fan rpm 3. Maximum cabinet static pressure 4. Maximum face velocity (cooling coil is not important) 5. Minimum furnace or electric heater velocity 6. Turndown capability on VAV applications 7. Compressor operating pressures Figure 13 illustrates these limiting factors with exception of items 6 and 7. The shaded area indicates the design operating range of the fan. For optimal efficiency, select fans as close to the fan s peak static efficiency line as possible. This line is the first system curve to the right of the unstable line illustrated. Figure 13: Fan Selection Boundary Fan Isolation All McQuay RoofPak systems feature internally isolated fans. All supply and return air fans are statically and dynamically balanced in the factory and mounted on rubber-in-shear (RIS) or 2 in. deflection spring isolators. Flexible isolation is provided as standard between the fan outlet and the discharge bulkhead to prevent hard contact and vibration transmission. Spring isolated fan assemblies are also available with seismic restraints. The choice of 2 in. deflection spring isolation or RIS isolation depends on an analysis of the roof structure and whether or not an isolation curb is being provided. When using an isolation curb, consult with the curb manufacturer before selecting spring isolation in the rooftop unit. Doubling or stacking spring isolation can cause a resonant vibration to be generated. Fan Heat Sensible heat gain from the supply and return fan, fan motor and drives occurs in all fan systems and must be considered in selecting rooftop equipment. It is an added load in cooling and an added source when in heating. Exhaust fan heat generally is not a cooling load or source of winter heat. The majority of the heat gain (95%) occurs through the fan itself, as the air is elevated from the lowpressure side to the high-pressure side of the fan. Moving the motor out of the air stream has a negligible effect on overall fan heat gain. A unit with higher fan power requirements/higher fan heat will have less net cooling capability and may not have enough left to satisfy system loads. As a rule of thumb, a typical supply fan heat gain is 3 F. However, fan heat gain can be quickly calculated once the fan has been selected and the fan brake horsepower has been determined. Using Figure 14, select your fan brake horsepower on the horizontal axis, move up vertically until you intersect with the heat gain curve and then move horizontally to find the fan heat gain in Mbh. Fan temperature rise = Fan Heat (Mbh)/(1.0 x Fan cfm) In addition to its effect on the sensible load of the system, where fan heat is introduced effects the sensible heat ratio capability of the rooftop system. Orientation of the fan and cooling coil determines if the heat gain is introduced as preheat or reheat. Figure 14: Fan and Motor Heat Gain Cat

28 Draw Through A draw through unit has the fan located after the DX cooling coil. In this arrangement, fan heat is applied as reheat to the cold, conditioned air coming off of the coil. This arrangement has a lower sensible heat ratio and higher dehumidification capability than a blow through coil arrangement. Draw through arrangements are well suited for 100% outside air applications and applications needing more dehumidification. A draw through arrangement is mandatory for all applications requiring final filters. The discharge temperature available to the supply duct is always the sum of the coil leaving air temperature plus the fan temperature rise. This must be considered when selecting the supply air volume required to satisfy space requirements. Example: 55 F leaving coil temp. + 3 F fan temp. rise = 58 F discharge air temp. All RFS and RPS units are available with a draw through configuration. Blow Through A blow-through unit has the fan located before the DX cooling coil. In this arrangement, fan heat is applied as preheat to the coil. Preheating the air lowers its relative humidity, giving this arrangement a high sensible heat ratio. Blow through arrangements are well suited for comfort conditioning applications where space heat gains are primarily sensible and the primary latent load is from ventilation air. The discharge temperature available to the supply duct is the coil leaving air temperature. All RFS and RPS036C - 135C units are available with a blow through configuration. Air Density Correction Fan Performance Fan performance data is based on standard 70 F air temperature and zero feet altitude (sea level). For applications other than standard, a density ratio must be multiplied to actual static pressure values. Density correction factors are expressed as a function of temperature and altitude in Table 5 on page 28. Table 5: Temperature and Altitude Conversion Factors Air Temp ( F) Altitude (Feet) Gas Heat Performance Gas heat performance data is based on standard 70 F air temperature and zero feet altitude (sea level). For applications other than standard, gas heat performance must be de-rated 4% for every 1,000 feet above sea level. System Operating Limits McQuay RoofPak systems are designed to operate over an extensive operating range, however, for proper system operation some limits do apply. To prevent moisture blow-off, design guidelines have been established for cooling coil selection. Based on laboratory testing, average coil face velocities should not exceed the following limits: 650 ft./min. for 8 & 10 fpi selections 600 ft./min. for selections For applications outside of these limits, consult your McQuay sales representative. Velocities exceeding these limits not only present the potential for moisture carry-over, but also high face velocities generate high air pressure drops, resulting in poor fan energy performance. In addition to maximum face velocity limitations, minimum velocity guidelines must also be followed. In order to maintain proper refrigeration performance, the minimum coil face velocity is 200 ft./min., regardless of coil fin spacing. When selecting a variable air volume unit, is necessary to design the system such that the 200 ft./min. limit is maintained at light load conditions. 28 Cat 214-5

29 Coil Freeze Protection When applying roof mounted equipment in geographic areas that experience subfreezing conditions, coil freeze protection measures must be provided. Subfreezing temperatures can adversely affect water and steam coils during controlled or uncontrolled unit shutdowns and even during unit operation. McQuay RoofPak economizer dampers are arranged to direct the outside and return air streams in multiple mixing patterns, minimizing air stratification. Even though this is one of the most effective mixing arrangements available, there may not always be a uniform unit temperature profile under all load and ambient temperatures. Some temperature stratification will occur, particularly at low ambient temperatures and the associated reduced airflow inherent with VAV systems. When required, static air mixers/blenders are available that can significantly improve mixing and reduce stratification. This can result in improved protection against freeze-up. Glycol is strongly recommended as a positive means of freeze protection for water coils. No control sequence can prevent coil freezing in the event of a power failure or equipment malfunction. During those periods, glycol is the only positive means of freeze protection. When selecting water coils, glycol should be specified to account for performance differences. An optional non-averaging freezestat equipment protection control can be provided, located downstream of the heating coil. If a potential freezing condition is sensed, a sequence is initiated by the unit control system, closing outdoor air dampers, opening the heating valve and deenergizing the fan. The freezestat setting should be some increment higher than freezing to provide an added margin of protection. The use of a freezestat control may cause nuisance trips. It cannot prevent freeze-up in the event of power failure or equipment malfunction. Freeze protection control strategies must be designed to keep unit cabinet temperatures from exceeding 150 F during a unit shutdown. Temperatures in excess of 150 F may exceed the design limits of motors, electrical components, gaskets, etc. potentially leading to premature failure of components. Piping and Condensate Drainage Always follow good industry practice in the design of the water piping system. Apply no undue stress at the connection to coil headers. In addition, piping should be supported independent from the coils with adequate piping flexibility for thermal expansion. Provide all drain pans with a properly sized p-trap to allow free drainage of coil condensate. Traps should be provided to prevent cabinet static pressure from leaking air at the drain line in blow-through coil applications. For draw through coil applications, a properly sized and installed trap is essential to allow for proper condensate drainage. An improper trap could cause condensate to build up in the drain pan and overflow into the unit. For trap sizing, follow instruction given in IM 4. All traps and drain lines should be run full size from the threaded unit connection to the roof drain. Units providing steam heat must be installed level to provide proper drainage and adequate steam pressure at steam valve and coil. Condensate must be properly trapped with vacuum breakers installed on the coil (See Figure 15). For steam piping recommendations, see McQuay Steam Coil Catalog 413. Figure 15: Drain Pan Traps Zone Sensor Placement Placement of the zone temperature sensor is critical for proper and economical operation of the heating and cooling system. It is generally recommended that the space sensor be located on an inside wall (3 to 5 feet from an outside wall) in a space having a floor area of at least 400 square feet. The sensor should not be located below the outlet of a supply diffuser, in the direct rays of the sun, on a wall adjacent to an unheated or abnormally warm room (boiler or incinerator room), or near any heat producing equipment. Where zone sensor placement is a problem, all zone control systems, as standard, have the capability to use a return air sensor for heating and cooling. Unit Wiring All units require three phase, 60 Hz, 208, 230, 460 or 5 volt power or three phase, 50 Hz, 400 volt power. Units will operate satisfactorily at ±10% of rated voltage, at the power connections to the units. All units include branch circuit fusing and are available with one or multiple power blocks or non-fused disconnect switches. Each unit is provided with a 115-volt convenience outlet circuit. Per the NEC, this circuit must be fed independent of the main unit power supply. All wiring must be installed in accordance with the National Electric Code (NEC) and local codes. Winter Shipment Flat bed shipment in winter can expose units to harsh road chemicals. Since equipment size and configuration precludes covering during transit, units should be washed free of these chemicals as soon as possible to prevent corrosion Cat

30 Unit Selection Achieving the optimal performance of a rooftop system requires both accurate system design and proper equipment selection. Factors which control the unit selection include applicable codes, ventilation and air filtration requirements, heating and cooling loads, acceptable temperature differentials, and installation limitations. McQuay RoofPak units offer a wide selection of component options providing the capability to meet diverse application requirements. The McQuay SelectTools software selection program allows your local McQuay sales representative to provide you with fast, accurate and complete selection of McQuay RoofPak units. Unit selection can also be accomplished through reference to physical, performance, dimensional and unit weight data included in this catalog. Due to the variety of cooling coil options available, only a sample of cooling capacity data has been presented in the catalog. Proper selection of unit equipment can be accomplished by following these three simple steps: 1. Select unit size and cooling coil 2. Select heating coils and equipment 3. Select fans and motors The following examples are provided to illustrate the equations and catalog references utilized in the unit selection process. Selection Example A constant volume system with DX cooling and natural gas heat. System design: Supply air volume 20,000 cfm Return air volume 16,000 cfm Minimum outside air volume 4,000 cfm Maximum face velocity 550 fpm Supply fan external SP 2.00 in. w.g. Return fan external SP. in. w.g. Altitude Sea level Economizer with return air fan 30% throwaway filters 460V/60Hz/3Ph Fully modulating heat Double wall construction Stainless steel drain pan Summer design: Space conditions F/50%Rh Space sensible load 435,000 Btu/hr Space total load 4,000 BTU/hr Space supply air temperature 55 F Ambient conditions 95 F/76 F Return sensible heat gain 2 F Est. Supply fan sensible heat rise 3 F Winter design: Return air temperature 70 F Ambient temperature 10 F Space heating load 450,000 Btu/hr Selection of Unit Size to Satisfy Summer Design Unit size is based on coil face area and cooling capacity requirements. Supply air capacity and maximum face velocity constraints should serve as a guide for selecting coil dimensions and cabinet size. Many model sizes are available with a standard and a high airflow coil selection. This flexibility prevents the need to increase cabinet size to accommodate high airflow per ton applications. Based on the given data, the appropriate coil face area may be determined as follows: Minimumfaceareasupplyairvolume/maximumfacevelocit = y =20,000 cfm/550 fpm =36.4 square feet Note: Unit data is based on standard air conditions of 70 F at sea level. Refer to Application Considerations on page 23 for temperature/altitude conversion factors for non-standard conditions. Referring to Physical Data on page 34, the 39.5 square foot, small face area coil of the RPS045C-0C units is found to satisfy the required face velocity. Plotting system conditions for a unit with a blow-through cooling coil on a Psychrometric Chart yields total summer cooling requirements (space + OA + return + supply fan) of: Mixed air temperature 81 F/66 F Coil entering air temperature 84 F/67 F (MAT+fan Τ) Supply fan volume 20,000 cfm Ambient air temperature 95 F Sensible cooling load 630,000 Btu/hr. Total cooling load 6,000 Btu/hr. Using the tables found in Cooling Capacity Data on page 38, the unit selection is an RPS060C with a small face area,, 12 fins/inch DX coil. Unit performance equals 8,000 Btu/hr Total, 636,000 Btu/hr Sensible. Supply air dry bulb = 84 F - 636Mbh/(1.0 x 20,000 cfm) = 55 F Once the initial unit selection has been made, the actual supply fan heat rise should be determined and the selection checked and verified for net capacity and supply air temperature. 30 Cat 214-5

31 Selection of Unit Heating System Heating equipment and coils can be specified directly from figures and tables incorporated in Heating Capacity Data on page 53. Calculating Total Heating Load Total heating load = space heating load + outdoor air load - supply fan heat. From the data given, the outdoor air load is 217 Mbh and supply fan heat is 65.1 MBH. Total heat load = 450 Mbh Mbh - 65 Mbh = 645 Mbh Gas Heat. When selecting a gas furnace, the system heating load, minimum airflow and maximum temperature rise constraints are needed. Refer to Figure 16 on page 53 for furnace model size selection. Enter the graph at 20,000 cfm and move up vertically to the intersection of 602 MBh output. In this example, the intersection of Minimum cfm and MBh Output occurs between model lines. Therefore, the larger model size, Model 640, should be selected for adequate heating. For all heat exchangers, there exist a maximum temperature rise. This limitation is determined by the heat exchanger surface area to airflow ratio. Refer to Table 40 on page 54 for verification of the temperature rise capability of the furnace selected. This table should also be used when specifying baffle position based on minimum airflow design. Note: In VAV applications, range of airflow modulation should be considered when selecting furnace model and baffle position. Hot Water Heat. Selection Example data along with other needed constraints shall be used to illustrate manual selection of unit hot water coils. The water temperature drop (t) is as follows: t Hot water capacity figures provided in Heating Capacity Data on page 53 are based on a standard initial temperature difference (ITD) of 140 F. The ITD value for the given example is determined as follows: ITD Hot water design: Entering water temperature Leaving water temperature 1 F 165 F = Ent. water temp. - Lvg. water temp. = = 15 F = Ent. water temp. - Ent. air temp. = 1-70 = 110 F Therefore, the specified capacity (Q t ) must be adjusted to the cataloged base conditions as follows: t b = t x 140/ITD = 15 x 140/110 = 19.1 F Enter Figure 17 on page 58 at 20,000 cfm and 17.5 F water temperature drop. Read a capacity of 820 MBh and water flow rate of 95 gpm for a low capacity coil. Correct the capacity to 110 ITD as follows: Q t = Q b x ITD/140 = 820 x 110/140 = 645 MBh Since the corrected capacity meets design, the low capacity hot water coil for the unit is acceptable. At a water temperature drop of 15 F, the water flow rate required is 95 gpm. Enter Figure 26 on page 60 at 105 gpm and select a valve size that has a pressure drop greater than 11.5 feet of water. The valve pressure drop should be as large as possible to maintain proper valve modulation. The valve pressure drop should be at least 50% of the total water pressure drop. If more than one valve selection meets the requirement, the valve size decision should be made based on first cost versus pumping head. The total water pressure drop of the unit water coil is the sum of the coil, valve, and valve piping. The pressure drop of the hot water coil including header is found in Figure 25 on page 59 for the given water flow rate. Valve and valve piping pressure drops are illustrated in Figure 26 and Figure 27 on page 60. For the given example, the total water pressure drop is as follows: Unit water coil pressure drops: Low capacity coil, 045C-0C 7.5 ft. of water 1-1/2 in. valve 19.0 ft. of water 1-1/2 in. valve piping 10.0 ft. of water Total water pressure drop 36.5 ft. of water The pressure drop of the 1-1/2 in. valve is 52% of the total pressure drop and shall be acceptable. If a glycol solution is to be used in the water coil, adjust for glycol performance factors for coil and valve sizing or contact your McQuay sales representative. Steam Heat. Selection Example data shall be used along with other needed constraints to illustrate manual selection of unit steam coils. Steam design: Steam supply pressure With an % pressure drop across the valve, the steam coil pressure is determined as follows: Steam coil pressure = 10 - (10 x 0.) = 2 psig Enter Figure 28 on page 61 at 20,000 cfm and 70 F entering air temperature. Move up vertically to the 2 psig curve and read a capacity of 730 MBh for the low capacity coil. This heating capacity meets design; therefore, the low capacity steam coil for the unit is acceptable. Valve size can be determined from the condensation rate of steam for a given coil pressure. Table 48 and Table 49 on page 63 have been provided to allow for manual steam valve selection for systems with atmospheric return mains and supply main pressure not exceeding 25 psig at stated conditions. For the given example, the appropriate valve size may be found as follows: Condensation Rate 10 psig = Capacity/Latent heat of steam = 730,000 / = 6 lbs./hr. Cat

32 Enter Table 49 on page 63, at 10 psig and 6 lbs./hr. The correct valve size is 1-1/2 in. Steam traps must be furnished and mounted in the field. Refer to Application Considerations on page 23 of this catalog or McQuay Steam Coil Catalog 413 for piping recommendations. Electric Heat. Referring to Electric Heat Capacity Table 47 on page 57 for the RPS060C, the design load of 645 Mbh falls between heater models 200 and 240. The Model 240 heater would be chosen to satisfy the design conditions. Selection of Fans and Motors Fan and motor selections are based on total static pressure drop and design airflow. Total static pressure includes internal air pressure drops of unit components and external air pressure drops in supply and return ducts. Refer to Component Pressure Drops on page 64 for internal pressure drops of unit components. Fan curves provided in Fan Performance Data - Supply Fans on page 68 and Fan Performance Data - Propeller Exhaust Fans on page 79 should be used when selecting unit fans and motors. To optimize fan performance, select the fan size having design airflow and static pressure intersecting as close to the first system curve after the shaded Do Not Select region as possible. Refer to Application Considerations on page 23 and Figure 8 on page 24 for illustration. When selecting motor size, the motor should be selected as close below the horsepower curve as possible to prevent motor oversizing. An oversized motor (large horsepower to load ratio) can greatly increase electric consumption due to the reduction in motor performance. Return Fan and Motor An economizer with a return fan must be selected for the given system. A return (or exhaust fan) system is often necessary for maintaining proper pressure in a building. Refer to Application Considerations on page 23 for further discussion on economizer, exhaust fan and return fan application. The external air pressure drop of the return duct along with the design return airflow are used to select a return fan. Based on Figure 64 on page 82, the optimal return fan size is 40 in. The required fan motor size is 5.0 hp. Exhaust Fan and Motor Exhaust fans must be sized for maximum exhaust CFM and return duct ESP at those conditions. See Fan Performance Data - Propeller Exhaust Fans on page 79 for more information. Supply Fan and Motor Since this system includes a return fan, the return duct static pressure drop is not added to the supply fan pressure drop. Therefore, the total static pressure for the supply fan in the Example is as follows: Internal pressure drops: 0-100% economizer, with RAF 0.33 in. w.g. 30% angular filters 0.14 in. w.g. Gas furnace Evaporative coil (small 5-row, ) Total internal pressure drop External pressure drops: Supply duct Total external pressure drop Total static pressure Note: When gas or electric heat is provided, do not add the cooling coil diffuser pressure drop. In VAV applications with gas heat, consult your McQuay sales representative for design pressure drop determinations. For a constant volume system a forward curve or airfoil type fan can be selected. Reference Application Considerations on page 23 for discussion on acoustical consideration. Considering its favorable brake horsepower, an airfoil type fan will be selected. Entering the standard 30 in. airfoil fan curve (see Figure 47 on page 73) at 20,000 cfm and 3.48 in. w.g., the required fan motor size is 20 hp operating at 1230 rpm. Fan brake horsepower is 16.2 horsepower. Supply Power Wiring Units Without Electric Heat Sizing supply power wire for a unit is based on the circuit with the largest amperage draw. All electrical equipment is wired to a central panel for single or optional multipower connections. Refer to Electrical Data on page 102 for FLA and RLA ratings of equipment. Determination of Minimum Circuit Ampacity (MCA) is as follows: Fans and Cooling: Therefore, 0.20 in. w.g in. w.g in. w.g in. w.g in. w.g. = internal drops + external drops = = 3.48 in. w.g. MCA = 1.25 x RLA or FLA of largest motor x FLA of other loads Example Compressor 1, 15 hp Compressor 2, 3, and 4 15 hp ea Condenser fan motors, (6) 1 hp Supply fan motor, 20 hp Return fan motor, 5 hp Select power supply wire based on 146 amperes. FLA/RLA 24 amps 24 amps ea 2 amps ea 25 amps 6.7 amps MCA = 1.25 x x [(4)24 + (6) ] = 146 amps 32 Cat 214-5

33 Supply Power Wiring for Units with Electric Heat When selecting units with nonconcurring electric heat, MCA must be calculated for both the cooling mode and the heating mode, and then the greater of the two used. For heating: MCA= 1.25 [FLA of electric heater + FLA of all other loads] = 1.25 x [ ] = 399 amps For cooling: MCA = 146 amps. The controlling load is when in the electric heat mode. Unit MCA = 399 amps. Calculating Unit Length Referring to unit Dimensional Data on page 84 for a blow-through RPS060C, Figure 73 on page 86: Note: Note: = 72 in in in in in in in. = 371 inches. When selecting unit curb length, do not include the length of the condensing unit. Calculating Unit Weight Referring to unit Unit Weights on page 109 for a RPS060C, Table 71 on page 110: Total unit weight= RPS basic unit + economizer + 30% filters + 30 AF SAF + 40 AF RAF + 5 row, Al. fin small face area coil mbh gas furnace + SAF motor + RAF motor + cabinet liners = (25 x 288/12) = 11,554 lbs. Total unit length = economizer w/raf + angular filter + fan section + heat section + DX coil section + discharge plenum + condensing unit Cat

34 Physical Data Table 6: Physical Data RPS015C-040C Data Nominal Capacity (tons) a Unit Size 015C 018C 020C 025C 030C 036C 040C Nominal Airflow (cfm) Compressor Condenser Coil (aluminum fins) Type Scroll Quantity - hp 1-6.7, , , , , Std. capacity control Rows/FPI 2/16 2/16 2/16 3/16 3/16 2/16 2/16 Face area (sq. ft.) No. - Dia. (In.) Condenser Fans Std. airflow (cfm) Cond. Fan Motors No. - Hp Supply Fans Return Fans Evaporator Coils Hot Water Coils Steam Coils Gas Furnace b Electric Heat c Panel Filters Prefilters (for Cartridge Filters) Cartridge Filters Type Forward Curved LP Forward Curved LP/MP No. - Dia. (In.) 2-15x6 2-15x6 2-15x6 2-15x6 2-15x No. - Dia. (In.) 2-15x x x x x Airflow Range (cfm) Motor hp range Type DWDI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) Airflow Range (cfm) Motor hp range Type Forward Curved Diameter (in.) 2-15x x x x x Airflow Range (cfm) Motor hp range Type SWSI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) , , 1-40 Airflow Range (cfm) Motor hp range Rows 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 FPI 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 F.A., small (sq. ft.) Type - Rows 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 Type - Rows 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 FPI Face area (sq. ft.) Type - Rows 5JA-1 5JA-1 5JA-1 5JA-1 5JA-1 5JA-1 5JA-1 FPI 6, 12 6, 12 6, 12 6, 12 6, 12 6, 12 6, 12 Face area (sq. ft.) Input (MBh) 250, 312, 400, 500, 625, 0, 812, 988, 1000, 1250 Nom. Output (MBh) 200, 250, 320, 400, 500, 640, 650, 790, 0, 1000 Nom. Output (kw) 20, 40, 60,, 100, 120, 140, 160, 1, 200, 220, 240 Type 30% Pleated Area (sq. ft.) No. - size (in.) 10-16x20x x25x x20x x25x x20x x25x x20x x25x x20x x25x x20x x25x2 a. Rated in accordance with ARI Standard 360 b. Gas furnace size availability is limited by minimum airflow, See Table 40: Gas Furnace Design Maximum Air Temperature Rise ( F) and Minimum Air Flow on page 54 c. Electric heat availability is limited by minimum airflow, See Table 42 through Table x20x x25x2 Type Prefilter, Standard Flow Area (sq. ft.) No. - size (in.) 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 4-24x24x2 4-12x24x2 Type 65% or 95%, Standard Flow Area (sq. ft.) No. - size (in.) 4-24x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x12 34 Cat 214-5

35 Table 7: Physical Data, RPS045C-0C Data Unit Size 045C 050C 060C 070 Scroll 070 Recip Nominal Capacity (tons) a Nominal Airflow (cfm) Compressor Condenser Coil (aluminum fins) Type Scroll Reciprocating Quantity - hp Std. capacity control Opt. capacity control Rows/FPI 2/16 2/16 2/16 2/16 2/16 Face area (sq. ft.) No. - Dia. (In.) Condenser Fans Std. airflow (cfm) Condenser Fan Motors No. - Hp Supply Fans Return Fans Exhaust Fans Evaporator Coils Hot Water Coils Type Forward Curve, LP/MP No. - Dia. (In.) 1-27, , , , , 33 Airflow Range (cfm) Motor hp range Type DWDI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) 1-27, , , , , 33 Airflow Range (cfm) Motor hp range Type SWSI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) Airflow Range (cfm) Motor hp range Type Propeller Diameter (In.) Quantity 1 or 2 per unit 1 or 2 per unit 1 or 2 per unit 1 or 2 per unit 1 or 2 per unit Motor hp 5 each 5 each 5 each 5 each 5 each Airflow Range (cfm) each (within cabinet limitations) Rows 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 FPI 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 F.A., small (sq. ft.) F.A., large (sq. ft.) Type - Rows 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 Type - Rows 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 FPI Face area (sq. ft.) Type - Rows 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 Steam Coils FPI 6, 12 6, 12 6, 12 6, 12 6, 12 Face area (sq. ft.) Gas Furnace b Input (MBh) 250, 312, 400, 500, 625, 0, 812, 988, 1000, 1250 Nom. Output (MBh) 200, 250, 320, 400, 500, 640, 650, 790, 0, 1000 Electric Heat c Nom. Output (kw) 40, 60,, 100, 120, 160, 200, 240 Panel Filters Prefilters (for Cartridge Filters) Type 30% Pleated Area (sq. ft.) No. - size (in.) 7-16x20x x25x2 7-16x20x x25x2 7-16x20x x25x2 7-16x20x x25x2 7-16x20x x25x2 Type Prefilter, Standard Flow Area (sq. ft.) No. - size (in.) 4-12x24x2 8-24x24x2 4-12x24x2 8-24x24x2 4-12x24x2 8-24x24x2 Prefilter, Medium Flow 4-12x24x2 8-24x24x2 4-12x24x2 8-24x24x2 Type Area (sq. ft.) No. - size (in.) 8-12x24x2 8-24x24x2 8-12x24x2 8-24x24x2 8-12x24x2 8-24x24x2 8-12x24x2 8-24x24x2 8-12x24x2 8-24x24x2 Cat

36 Table 7: Physical Data, RPS045C-0C Cartridge Filters Data Type 65% or 95%, Standard Flow Area (sq. ft.) No. - size (in.) 4-12x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x12 Type 65% or 95%, Medium Flow Area (sq. ft.) No. - size (in.) 8-12x24x x24x x24x x24x12 Unit Size 045C 050C 060C 070 Scroll 070 Recip 8-12x24x x24x x24x x24x x24x x24x12 a. Rated in accordance with ARI Standard 360 b. Gas furnace size availability is limited by minimum airflow, See Table 40: Gas Furnace Design Maximum Air Temperature Rise ( F) and Minimum Air Flow on page 54 c. Electric heat availability is limited by minimum airflow, See Table 42 through Table 44. Table 8: Physical Data, RPS0C-135C Data Unit Size 0S 0R 0C 090C 105C 115C 125C 135C Nominal Capacity (tons) a Nominal Airflow (cfm) Compressor Condenser Coil (aluminum fins) Condenser Fans Condenser Fan Motors Supply Fans Return Fans Exhaust Fans Evaporator Coils Type Reciprocating Quantity - hp , Std. capacity control Opt. capacity control Rows/FPI 2/16 2/16 2/16 2/16 2/16 2/16 2/16 2/16 Face area (sq. ft.) No. - Dia. (In.) St. airflow (cfm) No. - Hp Type Forward Curved, LP/MP No. - Dia. (In.) 1-30, , , , , , , , 40 Airflow Range (cfm) Motor hp range Type DWDI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) 1-30, , , , , , , , 40 Airflow Range (cfm) Motor hp range Type SWSI Airfoil, With or Without Variable Inlet Vanes No. - Dia. (In.) Airflow Range (cfm) Motor hp range Type Propeller Diameter (In.) Quantity 1-2 per unit 1-2 per unit 1-3 per unit 1-3 per unit 1-3 per unit 1-3 per unit 1-3 per unit 1-3 per unit Motor hp 5 each 5 each 5 each 5 each 5 each 5 each 5 each 5 each Airflow range (cfm) each (within cabinet limitations) Rows 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 3, 4, 5 FPI 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, 12 8, 10, F.A., small (sq. ft.) F.A., large (sq. ft.) Cat 214-5

37 Table 8: Physical Data, RPS0C-135C Hot Water Coils Steam Coils Gas Furnace b Electric Heat c Panel Filters Data Prefilters (for Cartridge Filters) Cartridge Filters Type - Rows 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 5WH-1 Type - Rows 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 5WS-2 FPI Face area (sq. ft.) Type - Rows 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 5JA-1, 2 FPI 6, 12 6, 12 6, 12 6, 12 6, 12 6, 12 6, 12 6, 12 Face area (sq. ft.) , 312, 400, Input (MBh) 500, 625, 0, 812, 988, 625, 0, 812, 988, 1000, 1250, 13, 10, 18, , 1250 Nom. Output (MBh) Nom. Output (kw) 200, 250, 320, 400, 500, 640, 650, 790, 0, , 60,, 100, 120, 160, 200, , 640, 650, 790, 0, 1000, 1100, 1400, 1500, 2000, 100, 120, 160, 200, 240, 2, 320 Type 30% Pleated Area (sq. ft.) No. - size (in.) 7-16x20x2 7-16x20x x20x x20x x20x x20x x20x x20x x25x x25x x25x x25x x25x x25x x25x x25x2 Type Prefilter, Standard Flow Prefilter, Medium Flow Area (sq. ft.) No. - size (in.) 4-12x24x2 8-24x24x2 4-12x24x2 8-24x24x2 4-12x24x x24x2 4-12x24x x24x x24x x24x x24x x24x2 Type Prefilter, Medium Flow Prefilter, High Flow Area (sq. ft.) No. - size (in.) 8-12x24x2 8-24x24x2 8-12x24x2 8-24x24x x24x x24x2 8-12x24x x24x2 8-12x24x x24x2 8-12x24x x24x2 8-12x24x x24x2 Type 65% or 95% Standard Flow 65% or 95% Medium Flow Area (sq. ft.) No. - size (in.) 4-12x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x12 Type 65% or 95% Medium Flow 65% or 95% High Flow Area (sq. ft.) No. - size (in.) Unit Size 0S 0R 0C 090C 105C 115C 125C 135C 4-12x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x x24x12 a. Rated in accordance with ARI Standard 360 b. Gas furnace size availability is limited by minimum airflow, See Table 40: Gas Furnace Design Maximum Air Temperature Rise ( F) and Minimum Air Flow on page 54 c. Electric heat availability is limited by minimum airflow, See Table 42 through Table x24x x24x12 Cat

38 Cooling Capacity Data Table 9: RPS015C Low Airflow Coil Unit Data 5000 cfm 6000 cfm 7000 cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 10: RPS018C Low Airflow Coil Unit Data 6000 cfm 7000 cfm 00 cfm Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 7 continues on the next page. a. Compressor kw Cat 214-5

39 Table 11: RPS020C Low Airflow Coil Unit Data 6000 cfm 00 cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 12: RPS025C Low Airflow Coil Unit Data 00 cfm cfm cfm Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw Table 8 continues on the next page Cat

40 Table 13: RPS030C Low Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 14: RPS036C Low Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat 214-5

41 Table 15: RPS040C Low Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 16: RPS045C Low Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat

42 Table 17: RPS050C Low Airflow Coil Unit Data 100 cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 18: RPS050C High Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat 214-5

43 Table 19: RPS060C Low Airflow Coil Unit Data cfm cfm cfm b Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 23,700 cfm Table 20: RPS060C High Airflow Coil Unit Data cfm cfm 200 cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat

44 Table 21: RPS 070C Low Airflow - Scroll Unit Data 100 cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 22: RPS070C Low Airflow Coil - Reciprocating Unit Data 100 cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 25,6 cfm Cat 214-5

45 Table 23: RPS070C High Airflow Coil - Scroll Unit Data cfm cfm 200 cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 24: RPS070C High Airflow Coil - Reciprocating Unit Data cfm cfm 200 cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat

46 Table 25: RPS0C Low Airflow Coil - Scroll Unit Data 100 cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 25,6 cfm Table 26: RPS0C Low Airflow Coil - Reciprocating Unit Data 100 cfm cfm cfm Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw Maximum airflow is 25,6 cfm b. Maximum airflow is 25,6 cfm Cat 214-5

47 Table 27: RPS0C High Airflow Coil - Scroll Unit Data cfm 10 fpi cfm 10 fpi cfm 10 fpi a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 28: RPS0C High Airflow Coil - Reciprocating Unit Data cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 25,6 cfm Cat

48 Table 29: RPS0C Low Airflow Coil Unit Data cfm 200 cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 30: RPS0C High Airflow Coil Unit Data 200 cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat 214-5

49 Table 31: RPS090C Low Airflow Coil Unit Data 200 cfm 10 fpi cfm 10 fpi cfm 10 fpi a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 32: RPS090C High Airflow Coil Unit Data 200 cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat

50 Table 33: RPS105C Low Airflow Coil Unit Data cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 39,520 cfm Table 34: RPS105C High Airflow Coil Unit Data cfm cfm cfm a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Cat 214-5

51 Table 35: RPS115C Low Airflow Coil Unit Data cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 39,520 cfm Table 36: RPS115C High Airflow Coil Unit Data 300 cfm cfm cfm b Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 45,600 cfm Cat

52 Table 37: RPS125C High Airflow Coil Unit Data cfm 10 fpi cfm 10 fpi 400 cfm 10 fpi a. Compressor kw Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a Table 38: RPS135C High Airflow Coil Unit Data cfm 10 fpi cfm 10 fpi cfm b 10 fpi Ambient Air Temperature ( F) Entering Air DB WB TH SH KW a TH SH KW a TH SH KW a a. Compressor kw b. Maximum airflow is 49,400 cfm Cat 214-5

53 Heating Capacity Data Gas Heat Figure 16: Gas Heat Capacity Table 39: RPS015C-135C Gas Furnace Air Temperature Rise ( F) Unit Size Nominal Airflow (cfm) Furnace Size (MBH Output) a C C C C C C C C C C C C C C C C C a. Output is % of input. Cat

54 Table 40: Gas Furnace Design Maximum Air Temperature Rise ( F) and Minimum Air Flow Maximum Temperature Rise ( F) Baffle Position Minimum Airflow (cfm) Column Number for Pressure Drop (See Table 55: Furnace Pressure Drop (in. W.C.) - RPS015C-135C on page 67) Furnace Size (MBh) A B C Note: Temperature rise and airflow limit applicable to all burner types. Note: For VAV application, consider the minimum turndown airflow when selecting baffle position. Table 41: Gas Burner Connection Size (inches) Description Furnace Size (MBh Output) Natural Gas (CFH) Minimum Gas Inlet Pressure (In. W.C.) Gas Pipe Connection Size (N.P.T.) Standard Burner :1 Burner Through.5 psi psi psi Cat 214-5

55 Electric Heat 208 Volts Table 42: RPS015C-040C-208V Electric Heat Air Temperature Rise ( F) Electric Heater Model Number Airflow (cfm) Electric Heater Capacity (MBH) n/a Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for unit sizes 015C-040C with electric heat is 6,000 cfm. Table 43: RPS045C-0C-208V Electric Heat Air Temperature Rise ( F) Electric Heater Model Number Airflow (cfm) Electric Heater Capacity (MBH) Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for unit sizes 045C-0C with electric heat is 14,000 cfm. Cat

56 Table 44: RPS0C-135C-208V Electric Heat Air Temperature Rise ( F) Electric Heater Model Number Airflow (cfm) Electric Heater Capacity (MBH) Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for units 0C-135C with electric heat is 22,000 cfm. 230, 460, and 5 Volts Table 45: RPS015C-040C-230,460, 5V Electric Heat Air Temperature Rise ( F) Airflow (CFM) Electric Heater Model Number * 200* 220* 240* Electric Heater Capacity (MBH) n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for units 015C-040C with electric heat is 6,000 cfm. Note: 1, 200, 220, and 240 electric heaters available at 460 or 5 Volts only. 56 Cat 214-5

57 Table 46: RPS045C-0C-230,460, 5V Electric Heat Air Temperature Rise ( F) Electric Heater Model Number Airflow (CFM) Electric Heater Capacity (MBH) Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for units 045C-0C with electric heat is 14,000 cfm. Table 47: RPS0C-135C-230,460, 5V Electric Heat Air Temperature Rise ( F) Electric Heater Model Number Airflow (cfm) Electric Heater Capacity (MBH) Note: The maximum temperature rise allowed for electric heat is 60 F with leaving air temperature not to exceed 140 F. Note: The minimum airflow required for units 0C-135C with electric heat is 22,000 cfm. Cat

58 Hot Water Heat RPS015C-040C Figure 17: Hot Water Coil, Low Capacity, RPS015C-040C Figure 19: Hot Water Coil Pressure Drop (Headers Included), RPS015C-040C Figure 20: Hot Water Valve and Piping Pressure Drop, RPS015C-040C Figure 18: Hot Water Coil, High Capacity, RPS015C-040C 58 Cat 214-5

59 RPS045C-135C Figure 21: Hot Water Coil, Low Capacity, RPS045C- 0C Figure 22: Hot Water Coil, High Capacity, RPS045C- 0C Figure 23: Hot Water Coil, Low Capacity, RPS0C- 135C Figure 24: Hot Water Coil, High Capacity, RPS0C- 135C Figure 25: Hot Water Coil Pressure Drop (Headers Included), RPS045C-135C Cat

60 Figure 26: Hot Water Valve Pressure Drop RPS045C-135C Figure 27: Hot Water Valve Piping Pressure Drop RPS045C-135C 60 Cat 214-5

61 Steam Heat Figure 28: Steam Coil, Low Capacity, RPS015C-040C Figure 29: Steam Coil, High Capacity, RPS015C-040C Figure 30: Steam Coil, Low Capacity, RPS045C-0C Figure 31: Steam Coil, Medium Capacity, RPS045C-0C Cat

62 Figure 32: Steam Coil, High Capacity, RPS045C-0C Figure 33: Steam Coil, Low Capacity, RPS0C-135C Figure 34: Steam Coil, Medium Capacity, RPS0C- 135C Figure 35: Steam Coil, High Capacity, RPS0C- 135C 62 Cat 214-5

63 Table 48: Saturated Steam Properties Pressure (psig) Temperature ( F) Latent Heat (Btu/lb.) Table 49: Steam Valve Selection Chart Condensate Rate, lb./hr. Valve Size (inches) Steam Supply Pressure a 5 psig 10 psig 15 psig 25 psig / / / a. Based on valve pressure drop of % of saturated steam supply pressure. Cat

64 Component Pressure Drops Table 50: RPS015C-040C (in. w.g.) Unit Airflow (cfm) Angular Rack 30% Pleated Pre- Filters Filter Evaporator Coils a Flat Rack 018C - 020C 025C - 040C 65% Cartr. 95% Cartr. 5-row 8 fpi 5-row 10 fpi 5-row 5-row 8 fpi 5-row 10 fpi 5-row 4, , , , , , , , , , , , , , , a. Pressure drop is for wet coil. Table 51: RPS015C-040C (in. w.g.) Unit Airflow (cfm) Dampers Coils Discharge Return Hot Water Steam 018C-030C 018C-030C Low Cap. High Cap. Low Cap. High Cap. Economizer Return Damper 100% O.A. Hood With Dampers 4, , , , , , , , , , , , , , , Cat 214-5

65 Table 52: RPS045C-0C Outdoor/Re turn Air Options a b Filter Options Plenum Options Cooling Options c d Heating Options c Airflow (cfm) Component 14,000 16,000 18,000 20,000 22,000 24,000 26,000 28,000 30, % outside air hood w/damper % outside air hood w/damper % economizer, w/o RAF % economizer, w/raf % pleated Prefilter, standard flow Prefilter, medium flow % cartridge, standard flow % cartridge, medium flow % cartridge, standard flow % cartridge, medium flow Return, isolation damper Discharge, isolation damper DX, low airflow, 5-row, 10 fpi DX, low airflow, 5-row, DX, high airflow, 5-row, 10 fpi DX, high airflow, 5-row, DX, high airflow, 6-row, 10 fpi f Cooling diffuser e Hot water, 1-row Hot water, 2-row Steam, 1-row, 6 fpi Steam, 1-row, Steam, 2-row, 6 fpi Electric heat Gas heat See Table 55: Furnace Pressure Drop (in. W.C.) - RPS015C-135C on page 67 a. Pressure drop through hood and damper is based on 30% of listed airflow. b. Pressure drop through the economizer assumes that all of the air will be passing through the return air dampers. c. Pressure drop through coils can be found in the McQuay selection program output. d. DX coil pressure drops are based on wet coils. e. A cooling diffuser is provided on units with blow-through cooling only. f. Only available on RPS 0 C with reciprocating compressors. Cat

66 Table 53: RPS0C-135C Outdoor/ Return Air Options a b Filter Options Plenum Options Airflow (cfm) Component 18,000 22,000 26,000 30,000 34,000 38,000 42,000 46,000 50, % outside air hood w/damper % outside air hood w/damper Economizer, w/o RAF Economizer, w/raf " throwaway % pleated Prefilter, standard flow Prefilter, medium flow Prefilter, high flow % cartridge, standard flow % cartridge, medium flow % cartridge, high flow % cartridge, standard flow % cartridge, medium flow % cartridge, high flow Return, isolation damper Discharge, isolation damper Cooling Cooling diffuser Options c Cooling coils See Table 54: Cooling Coil Air Pressure Drops-RPS0C-135C on page 66 Hot water, 1-row Hot water, 2-row Heating Options d Steam, 1-row, 6 fpi Steam, 1-row, Steam, 2-row, 6 fpi Electric heat Gas heat See Table 55: Furnace Pressure Drop (in. W.C.) - RPS015C-135C on page 67 a. Pressure drop through hood and damper is based on 30% of listed airflow. b. Pressure drop through the economizer assumes that the majority of air will be passing through the return air dampers. If large quantities of outside air are required, pressure drops will increase causing airflow to decrease. c. A cooling diffuser is provided on units with blow-through cooling only. d. Pressure drop through coils can be found in the McQuay selection program output. Table 54: Cooling Coil Air Pressure Drops-RPS0C-135C Unit Size Cooling Coil Airflow (cfm) DX, low airflow, 5-row, 10fpi C- 090C 105C- 135C DX, low airflow, 5-row, 12fpi DX, high airflow, 5-row, 10fpi DX, high airflow, 5-row, 12fpi DX, low airflow, 5-row, 10fpi DX, low airflow, 5-row, 12fpi DX, high airflow, 5-row, 10fpi DX, high airflow, 5-row, 12fpi Note: DX coil pressure drops are based on wet coils. Note: Pressure drop of cooling coils not shown can be found in the McQuay selection program output. 66 Cat 214-5

67 Table 55: Furnace Pressure Drop (in. W.C.) - RPS015C-135C Airflow (cfm) Column Number See Table 40 on page Table 56: Gravity Relief Damper Air Pressure Drop % Economizer Exhaust CFM Size Size Size Note: If all exhaust must occur through the economizer gravity relief damper, and no return or exhaust fan is provided, then the building may be pressurized by the sum of the return duct pressure drop plus the gravity relief pressure. Cat

68 Fan Performance Data - Supply Fans Figure 36: RPS/RFS015C-030C (2) 15 in.x6 in. Forward Curved Supply Fan Figure 37: RPS/RFS015C-030C (2) 15 in.x15 in. Forward Curved Supply Fan 68 Cat 214-5

69 Figure 38: RPS/RFS015C-030C 20 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 39: RPS/RFS015C-030C 20 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Cat

70 Figure 40: RPS/RFS036C-040C 24 in. Forward Curve Supply Fan Class II Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 41: RPS/RFS036C-040C 24 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). 70 Cat 214-5

71 Figure 42: RPS/RFS036C-040C 24 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 43: RPS/RFS045C-050C 27 in. Forward Curved Supply Fan Class II Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Cat

72 Figure 44: RPS/RFS045C-050C 27 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 45: RPS/RFS045C-050C 27 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). 72 Cat 214-5

73 Figure 46: RPS/RFS045C-0C 30 in. Forward Curved Supply Fan Class II Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 47: RPS/RFS045C-0C 30 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Cat

74 Figure 48: RPS/RFS045C-0C 30 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 49: RPS/RFS060C-0C 33 in. Forward Curved Supply Fan Class II Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). 74 Cat 214-5

75 Figure 50: RPS/RFS060C-0C 33 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 51: RPS/RFS060C-0C 33 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Cat 214-5

76 Figure 52: RPS/RFS0C-090C 33 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 53: RPS/RFS0C-090C 33 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). 76 Cat 214-5

77 Figure 54: RPS/RFS0C-135C 36 in. Airfoil Supply Fan without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 55: RPS/RFS0C-135C 36 in. Airfoil Supply Fan with Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Cat

78 Figure 56: RPS/RFS105C-135C 40 in. Airfoil without Vanes Note: Maximum allowable static pressure at fan bulkhead is 5.0 in (i.e., ESP plus blow-through component pressure drops cannot exceed 5.0 in). Figure 57: RPS/RFS105C-135C 40 in. Airfoil with Vanes 78 Cat 214-5

79 Fan Performance Data - Propeller Exhaust Fans Figure 58: RPS/RFS045C-135C (1) 36 in. Propeller Exhaust Fan # 4 2 % # # - N JA H = 5 J= JE? 2 H A I I K H A E M C # % # ' & % " # $ > D F # $! # # " " $ & " $ & ) EH B M? B Figure 59: RPS/RFS045C-135C (2) 36 in. Propeller Exhaust Fan # 4 2 % # - N JA H = 5 J= JE? 2 H A I I K H A E M C # # % # # ' & % $ * 0 2 & # $ # " " " & $ " &!! $ " ) EH B M? B Cat

80 Figure 60: RPS/RFS0C-135C (3) 36 in. Propeller Exhaust Fan # 4 2 % # - N JA H = 5 J= JE? 2 H A I I K H A E M C # # % # # ' & % $ # & * 0 2 # ' # " $! $ & "!! $ " " & # " $ ) EH B M? B Cat 214-5

81 Fan Performance Data - Return Fans Figure 61: RPS/RFS015C-030C, (2) 15 in.x15 in. Forward Curved Return Fan Figure 62: RPS/RFS015C-040C, 30 in. Airfoil Return Fan without Vanes Figure 63: RPS/RFS015C-040C, 30 in. Airfoil Return Fan with Vanes Back return performance correction. For 30 in. airfoil fan with back return, add the following static pressure to the design return duct static pressure. Enter Figure 63 and Figure 62 at this greater static pressure and the design airflow to determine actual back return performance. Additional back return static pressure, 30 in. airfoil with or without vanes. Airflow (cfm) 4,000 6,000 8,000 10,000 12,000 14,000 Back Return SP (in. W.G.) Cat

82 Figure 64: RPS/RFS036C-040C, 40 in. Airfoil Return Fan without Vanes (Bottom Return Only) Figure 65: RPS/RFS036C-040C, 40 in. Airfoil Return Fan with Vanes (Bottom Return Only) Figure 66: RPS045C-0C 40 in. Airfoil Return Fan without Vanes! 5 J= JE? 2 HA I I K HA E M C # # # % $ # " " $ & " $ & " $ &!!! " ) EHB M? B 82 Cat 214-5

83 Figure 67: RPS045C-0C 40 in. Airfoil Return Fan with Vanes! 5 J= JE? 2 HA I I K HA E M C # # # % $ # "! & " $ & " $ & " $ &!!! " ) EHB M? B # ' % # # #! * 0 2 # Figure 68: RPS0C-135C, Standard 44 in. Airfoil Return Fan without Vanes 5 J= JE? 2 HA I I K HA E M C! # # # $ # % & # ' #! " $ * 0 2 # 4 2 % # # " & $ " &!! $ " " " " & # ) EHB M? B Figure 69: RPS0C-135C 44 in. Airfoil Return Fan with Vanes! 5 J= JE? 2 HA I I K HA E M C # # # $ # % # % # & ' # #! " # 4 2 $ * 0 2 " & $ " &!! $ " " " " & # ) EHB M? B Cat

84 Dimensional Data Section Options and Locations Figures show section options, curb lengths, and relative positions. Curb lengths (in inches) are shown below each icon. Figure 70: RPS/RFS/RCS015C-030C - Draw-through Coil Section 84 Cat 214-5

85 Figure 71: RPS/RFS/RCS036C and 040C Blow-through Coil Section (NA Final Filters) Figure 72: RPS/RFS/RCS036C and 040C Draw-through Coil Section Cat 214-5

86 Figure 73: RPS/RFS/RCS045C-0C Blow-through Coil Section (NA Final Filters) Outdoor/ Return Air Mandatory Filter Mandatory Blank Optional Supply Air Fan Mandatory Heat Mandatory Blank Optional DX Coil Mandatory Discharge Plenum Mandatory Blank Compartment Optional Air-cooled Condensing Unit Outdoor Air Hood Angular Blank 045C-050C 27 & 30 Dia Steam/Hot Water Blank 045C (39.5 sq. Ft.) Discharge Plenum 070C-0C Blank Compartment 045C-060C Air-cooled Condenser 0 Plenum 24 Cartridge (40 sq. Ft) 48 VFD Section C-0C 30 Dia 48 Electric 48 Sound Attenuator C-0C (39.5 sq. ft.) (Does not affect curb length) 48 30% Outside Air 24 Cartridge (48 sq. Ft.) Dia 48 Gas 48 Sound Attenuator* 24 (47.1 sq. ft.) 070C-0C Air-cooled Condenser 48 Economizer 48 Blender & Angular or 40 sq ft Cartridge Blank (Does not affect curb length) 72 Economizer w/ Return Air Fan 72 Blender & 48 sq ft Cartridge Econ w/ Prop. Exh. Fans, Bottom or Back Ret. Fans 96 Blank 72 Econ w/ Prop. Exh. & Side Ret. Fans 24 or Figure 74: RPS/RFS/RCS045C-0C Draw-through Coil Section Outdoor/ Return Air Mandatory Filter Mandatory Blank Optional DX Coil Mandatory Supply Air Fan Mandatory Heat Mandatory Blank Optional Final Filter Optional Discharge Plenum Mandatory Blank Compartment Optional Air-cooled Condensing Unit Outdoor Air Hood Angular Blank 045C (39.5 sq. Ft.) 045C-050C 27 & 30 Dia Steam/ Hot Water Blank Cooling Only, Steam or Hot Water (40 sq. Ft.) Discharge Plenum 070C-0C Blank Compartment 045C-060C Air-cooled Condenser 0 Plenum 24 Cartridge (40 sq. Ft.) 48 VFD Section C-070C (39.5 sq. Ft.) C-0C 30 Dia 48 Electric 48 Cooling Only, Steam or Hot Water Sound Attenuator 48 Gas or Electric Heat (48 sq. Ft.) (Does not affect curb length) 070C-0C 48 30% Outside Air 48 Economizer 24 Cartridge (48 sq. Ft.) 48 Blender & Angular or 40 sq ft Cartridge (47.1 sq. ft.) Dia Gas 48 Blank 48 Gas or Electric Heat Sound Attenuator* 72 Blank 48 Air-cooled Condenser 119 (Does not affect curb length) 72 Blank 72 Economizer w/ Return Air Fan 72 Blender & 48 sq ft Cartridge Econ w/ Prop. Exh. Fans, Bottom or Back Ret. Fans Blank 24 or Econ w/ Prop. Exh. & Side Ret. Fans 120 Note: Exhaust Fan Section dimensions do not include the hood. See page Cat 214-5

87 Figure : RPS/RFS/RCS0C-135C Blow-through Coil Section (NA Final Filters) Outdoor/ Return Air Mandatory Filter Mandatory Blank Optional Supply Air Fan Mandatory Heat Mandatory Blank Optional DX Coil Mandatory Discharge Plenum Mandatory Blank Compartment Optional Air-cooled Condensing Unit Outdoor Air Hood Angular Blank 0C-090C 33 Dia Steam/ Hot Water Blank 0C-090C (53.9 sq. Ft.) Discharge Plenum Blank Compartment 0C-105C Air-cooled Condenser 0 Plenum 24 Cartridge (56 sq. Ft.) (0C-090C only) 48 VFD Section Dia 48 Electric 48 Sound Attenuator 24 (60.8 sq. Ft.) (Does not affect curb length) 115C-135C 72 30% Outside Air 24 Cartridge (64 sq. Ft.) (0C-135C only) C-115C 36 & 40 Dia 48 Gas 48 Sound Attenuator* C-115C (60.8 sq. Ft.) Air-cooled Condenser 72 Economizer 48 Cartridge ( sq. Ft.) (105C-135C only) Blank (76.0 sq. Ft.) 139 (Does not affect curb length) Economizer w/ Return Air Fan 72 Blender & Angular or 56 sq ft Cartridge C-135C (76.0 sq. Ft.) Econ w/ Prop. Exh. Fans, Bottom or Back Ret. Fans Blender & 64 sq ft Cartridge Econ w/ Prop. Exh. & Side Ret. Fans 96 Blank or 48 Figure 76: RPS/RFS/RCS0C-135C Draw-through Coil Section Outdoor/ Return Air Mandatory Filter Mandatory Blank Optional DX Coil Mandatory Supply Air Fan Mandatory Heat Mandatory Blank Optional Final Filter Optional Discharge Plenum Mandatory Blank Compartment Optional Air-cooled Condensing Unit Outdoor Air Hood Angular Blank 0C-090C (53.9 sq. Ft.) 0C-090C 33 Dia Steam/ Hot Water Blank Cooling Only, Steam or Hot Water (56 sq. Ft.) (0C-090C only) Discharge Plenum Blank Compartment 0C-105C Air-cooled Condenser 0 Plenum 72 30% Outside Air 24 Cartridge (56 sq. Ft.) (0C-090C only) 24 Cartridge (64 sq. Ft.) (0C-135C only) 48 VFD Section (60.8 sq. Ft.) C-115C Dia C-135C 48 Electric 48 Gas 48 Cooling Only, Steam or Hot Water Sound Attenuator Gas or Electric Heat (64 sq. Ft.) (Does not affect curb length) 115C-135C Air-cooled Condenser 72 Economizer 48 Cartridge ( sq. Ft.) (105C-135C only) (60.8 sq. Ft.) 48 (76.0 sq. Ft.) 36 & 40 Dia Blank Gas or Electric Heat Sound Attenuator* ( sq. Ft.) (105C-135C only) (Does not affect curb length) Blank Economizer w/ Return Air Fan Blender & Angular or 56 sq ft Cartridge C-135C 48 (76.0 sq. Ft.) Blank Econ w/ Prop. Exh. Fans, Bottom or Back Ret. Fans Blender & 64 sq ft Cartridge Econ w/ Prop. Exh. & Side Ret. Fans 96 Blank or 48 Note: Exhaust Fan Section dimensions do not include the hood. See page 99. Cat

88 Use Figure 70 through Figure 76 to determine the total air handler length and total unit length. The total air handler length is needed to determine roof curb knockouts. The total air handler length incudes all unit sections except the air cooled condensing section. Example: RPS 045C with Draw-through Coil Section (from Figure 78) Section Description Length (in.) Economizer with return air fan 72 Angular filters 24 Cooling coil 24 Supply fan 72 Gas heat 48 Final filter, standard flow 48 Discharge plenum 48 Air cooled condensing unit 83 Total air handler length = 336 Total unit length (including condensing 419 unit)= Consult you local McQuay sales representative for a custom certified drawing of your specific requirements. Table 57: RPS/RFS015C-040C Return Air Opening Size Unit Size Return Air Selection Bottom Return Back Return A B C D E Plenum, with or without 30% OA Hood RPS/RFS/015C-040C Economizer Economizer with 2-15 in. x 15 in. RAF Economizer with 30 in. RAF RPS/RFS036C-040C Economizer with 40in. RAF NA NA 88 Cat 214-5

89 Figure 77: RPS/RFS/RCS015C-040C Typical Configuration! & + ) 5 K F F O ) EH F A E C # 2 6, H= E $! & 7 EJ5 D M $ + 4 A JK H ) EH2 K ) C K = H E JA H5 A? JE " 5 K F F O ) EH = 0 A = J M ) EHB M, : + E 5 A? JE, EI? D = HC A 2 A K ' " - * % $ & $ # * =? 4 A JK H F A E C F JE =! & + 4 A JK H ) EH 2 A K * JJ 4 A JK H F A E C! & A A, A J= E!! & K F F O = 0 A = J5 A? JE, EI? D = HC A ) EH 2 A K # " " "! & H J F A E C F JE = -, O # # #, % &! $ E JA H5 A? JE 4 5 & %, H= E + A? JE! $ = E + JH 2 = A - L = F + E I Note: 1. Unit length varies depending on the configuration (sections and options ordered). See Figure 70 through Figure 72 for air handler section lengths. 2. Figures illustrate an RFS/RCS configuration. An RPS would be a single piece. Figure 78: RPS/RFS/RCS045C-0C Note: 1. Unit length varies depending on the configuration (sections and options ordered). See Figure 73 through Figure 74 for air handler section lengths. 2. Figures illustrate an RFS/RCS configuration. An RPS would be a single piece. Cat

90 Figure 79: RPS/RFS/RCS0C-090C & $! & 5 K F F O ) EH F A E C # 2 6, H= E & $ & 7 EJ5 D M $ + 4 A JK H ) EH2 K ) C K = H E JA H5 A? JE! 5 K F F O ) EH = 0 A = J M ) EHB M, : + E 5 A? JE, EI? D = HC A 2 A K ' ' '! # & % & '! # * =? 4 A JK H F A E C F JE = & $ 4 A JK H ) EH 2 A K * JJ 4 A JK H F A E C $ " A A, A J= E! " % K F F O = 0 A = J5 A? JE, EI? D = HC A ) EH 2 A K " & " " " & " & " " & & &! H J F A E C F JE = 4 5 O &! %!! &! & % & % E JA H5 A? JE 4 5 ", H= E + A? JE % = E + JH 2 = A - L = F + E I Figure : RPS/RFS/RCS105C-135C Note: 1. Unit length varies depending on the configuration (sections and options ordered). See Figure through Figure 76 for air handler section lengths. 2. Figures illustrate an RFS/RCS configuration. An RPS would be a single piece. 3. RPS105C condensing section is 119 in. 90 Cat 214-5

91 Electrical Knockout Locations Figure 82: Electric Heat/Heat Section Figure 81: Main Control Panel/Discharge Plenum 4 A BA HA? A BH A = L E C = BI A? JE & &!, E= 3 JO! % $ ', E= 3 JO " ' ' #! % % & %! "! $ $!, E= 3 JO ', E= '!!!! % $ $ % $ & & Piping Entrance Locations Note: RPS045C-135C only 208/230/60/3, >160kW only Figure 83: Steam and Hot Water Heat/Heat Section Figure : MBH Gas Heat/Heat Section 120 to 1400 MBH A l Piping Entrance Holes Should Fa l W ithin This Area UnitSize A B C D 015C -040C C -135C B A R ecom m ended Piping Entrance (Through the Curb) D C UnitSize A B C D 015C -030C C -135C B A Figure 84: MBH Gas Heat/Heat Section # * 0 C D 4 A? 2 EF E C - JH=? A 4 B2 EJ? D 2? A J4 A G K & Cat

92 Roof Curbs Figure 86: Roof Curb, RPS/RFS015C - 040C (without blank compartment) + ) $ &, # $ O * 4 ) 2 / 5 ) 2 / % $ ' % * * ), 6 O F " 6 O F ) 7 EJ A C JD E K I $ " 5 A A? K J, A J= E % # $ ' & Note: Roof Curb must be installed level. Figure 87: Roof Curb, RPS/RFS015C - 040C (with blank compartment), + ) " $ & $ & # $ O * 4 ) 2 / 5 ) 2 / % $ ' % * * ), 6 O F " 6 O F ) 7 EJ A C JD E K I $ " 5 A A? K J, A J= E % # $ ' & Table 58: RPS/RFS015C-040C Roof Curb Dimensions Figure 88: Detail B Model Return Fan A (in.) B (in.) C (in.) D (in.) E (in.) None C-030C (2) 15 in. FC in. AF None C-040C 30 in. AF in. AF Figure 89: RPS/RFS015C-040C Curb Section A-A Figure 90: RPS/RFS015C-040C Curb Section B-B 92 Cat 214-5

93 Figure 91: Roof Curb, RPS/RFS045C-135C (without blank compartment) Note: Roof Curb must be installed level. Figure 92: Roof Curb, RPS/RFS045C-135C (with blank compartment) Table 59: RPS/RFS045C-135C Variable Dimensions Figure 93: Detail B MODEL SIZE D: SUPPLY AIR OPENING C: RETURN AIR OPENING B 045C-0C RPS 0C-090C C-135C Figure 94: RPS/RFS045C-135C Curb Section B-B Figure 95: RPS/RFS045C-135C Curb Section A-A Cat

94 Figure 96: RCS Roof Installation RCS UNIT SIZE ZZ IN. MM 015C 030C C & 040C C 060C C 0C $ ) * ) $ $ * ) ) $ = E + H I I 5 A? JE # % $ " & "! # 7 EJ* = I A / = L = E + K H>! / = L = E + K EH> + L A H " N " = E A H5 JHEF # 4 EC E@ 1 I K = JE JBK H EI D $ + = J5 JHEF JBK H EI D % = I D E C JBK H EI D & + K H> / = I A JE C ' 1 I K = JE > A JM A A / = L = E + K H> JBK H EI D 4 BE C = JA HE= JBK H EI D ' 94 Cat 214-5

95 Figure 97: RFS/RCS Refrigerant Piping Connections ; : 0 / 5 0 / 5 5 : ; 0 / 0 / 5 Figure 98: RFS/RCS 036 & 040 Refrigerant Piping Connections ; 0 / 0 / : 0 / 5 5 : ; / Table 60: S1 Component Circuit Suction Line Connection Sizes 015C 020C 025C 030C- 040C Connection Locations RCS 036 RFS/RFR RCS RFS/RFR 036 & 040 & 040 X (in.) Y (in.) X (in.) Y (in.) X (in.) Y (in.) X (in.) Ckt.1 1-1/8 1-1/8 1-5/8 1-5/ S2 Suction Line Ckt.2 1-3/8 1-5/8 1-3/8 1-5/ L1 Liquid Line Ckt.1 5/8 5/8 7/8 7/ L2 Liquid Line Ckt.2 7/8 7/8 7/8 7/ HG1 HGBP Line Ckt.1 7/8 7/8 7/8 7/ HG2 HGBP Line Ckt.2 7/8 7/8 7/8 7/ Cat

96 Figure 99: Split Unit Physical Data--RFS, RCS RPS Split at Condensers (045C-135C) ; ; : : Note: This figure illustrates piping locations for and RPS split at the condenser section and for an RFS/RCS construction. Table 61: Connection Sizes and Locations Connection Sizes Component Circuit 045C 050C - 0C 0C - 90C 105C - 135C Connection Locations RPS (Split) RFS/RFR 045-0C RCS 045-0C X (in.) Y (in.) X (in.) Y (in.) S1 Suction Line Ckt.1 1-5/8 2-1/8 2-1/8 2-5/ S2 Suction Line Ckt.2 1-5/8 2-1/8 2-1/8 2-5/ L1 Liquid Line Ckt.1 7/8 7/8 1-1/8 1-1/ L2 Liquid Line Ckt.2 7/8 7/8 1-1/8 1-1/ HG1 HGBP Line Ckt.1 7/8 7/8 7/8 7/ HG2 HGBP Line Ckt.2 7/8 7/8 7/8 7/ Cat 214-5

97 Horizontal Duct Connections See Figure 77 & Figure 78 on page 89 and Figure 79 & Figure on page 90 for Back return without exhaust fans. Figure 100: RPS/RFS Cabinet Height A B 015C-040C C-0C C-135C Figure 101:Internal Cabinet Clearance, Air in the Face RPS/RFS C D E F 015C-040C C-0C C-135C C= Ceiling-to-floor (with liners) D= Door-to-door (with liners) E=Upright-to-upright, located between sections F=Base-to-base Cat

98 Figure 102:RPS 045C - 0C - Back Return Propeller Exhaust Fans (2 shown) Figure 103:RPS 045C - 0C - Side Return Propeller Exhaust Fans 98 Cat 214-5

99 Figure 104:0C - 135C - Back Return Propeller Exhaust Fans Figure 105:0C - 135C - Side Return Propeller Exhaust Fans Cat

100 Recommended Clearances Service Clearance Allow recommended service clearances shown in Figure 106. Provide a roof walkway along two sides of the unit for service and access to most controls. Figure 106:Service Clearances Additional clearance, A, is recommended adjacent to the cooling coil, heat, and supply fan sections. See Figure 70 on page 84 through Figure 76 on page 87to identify these sections. Table 62: Service Clearance Unit Size A B C 015C-040C C-135C Overhead Clearance Cooling coil, heat and supply fan service clearance 1. Unit(s) surrounded by screens or solid walls must have no overhead obstructions over any part of the unit. 2. Area above condenser must be unobstructed in all installations to allow vertical air discharge. 3. The following restrictions must be observed for overhead obstructions above the air handler section: a. There must be no overhead obstructions above the furnace flue, or within 9 in. of the flue box. b. Any overhead obstruction shall not be within 2 in. of the top of the unit. c. A service canopy must not protrude more than 24 in. beyond the unit in the area of the outside air and exhaust dampers. Figure 107: Ventilation Clearances Ventilation Clearance Unit(s) surrounded by a screen or a fence: 1. The bottom of the screen should be a minimum of 1 ft. above the roof surface. 2. Minimum distance, unit to screen same service clearance. 3. Minimum distance, unit to unit in. Unit(s) surrounded by solid walls: 1. Minimum distance, unit to wall - 96 in., all sizes 2. Minimum distance, unit to unit in. 3. Wall height restrictions: a. Wall on one side only or on two adjacent sides - no restrictions. b. Walls on more than two adjacent sides - wall height not to exceed unit height. 100 Cat 214-5