Installation & Maintenance Data IM 254-4 Group: Fan Coil Part Number: 107133000 Date: June 1999 SeasonMaker HiLine Fan-coil Units Type KZZ Contents Inspection..................................... 2 Riser Installation................................ 2 Unit Installation............................... 3, 4 Start-up....................................... 7 Maintenance................................... 8 Service....................................... 8 Replacement Parts.............................. 8 1999 McQuay Incorporated
Installation and maintenance are to be performed only by qualified personnel who are familiar with and in compliance with state, local and national codes and regulations, and experienced with this type of equipment. Caution: Sharp edges and coil surfaces are a potential injury hazards. Avoid contact with them. Inspection When the equipment is received, all items must be carefully checked against the bill of lading to be sure all crates and cartons have been received. The units are shipped four to a pallet. Visible or concealed damage should be reported immediately to the carrier along with the filing of a claim for damage. The electrical nameplate should be checked to be sure it agrees with the power supply available. See Figure 1 below. Riser Installation (Field Supplied & Installed) 1. It is critical that the coupling stub-outs are properly positioned so that the coil connections will line up when the units are placed in position. See Figure 2. It is recommended that a fixture be constructed to maintain dimensions shown in Figure 2 during the soldering process. 2. If isolator pads are required, this additional thickness must be considered before installation of risers. 3. Due to expansion or contraction, the unit has provisions for plus or minus one inch vertical movement of risers. If the riser system movement exceeds this value, compensating provisions must be provided by the installing contractor. 4. Risers must be anchored to the building as there is no provision on the unit to support the weight of the risers. 5. Care must be taken to prevent dirt and other foreign matter from entering the risers as clogged lines or valves could result. 6. Close all ball valves on the coupling stub-outs and cement joints to avoid condensation problems. 7. Apply insulation to stub-outs and cement joints to avoid condensation problems. 8. To assure compliance with existing building codes, the installing contractor must restore the original fire resistance rating of the structure by sealing the access space around the risers with material having the same fire rating at the structure. This procedure is very important also in assuring that a seal is provided between floors to prevent the passage of warm, humid air which can cause condensation on riser insulation. This is most critical in unpressurized buildings with high infiltration rates. Figure 1. Uncrating Figure 2. Field riser locations 20" (508 mm) (Cabinet) 20" (508 mm) 3-1/2" (89 mm) 3-1/2" (89 mm) 11/32" (9 mm) Plaster Stop 3-1/2" (89 mm) 3-5/8" (92 mm) 3-1/8" (79 mm) 2-3/4" (70 mm) 1/16" (2 mm) Htg. Supply Clg. Supply Htg. Return Clg. Return 43-1/2" (1105 mm) 3-1/4" (83 mm) 2-Pipe System XXX 3/8" (9.5 mm) YYY 3/4" (19 mm) Floor Drain Page 2
1. The KZZ HiLine fan-coil units have been received with the top plenum and plenum front cover not assembled to the lower cabinet (see Figure 3). 2. Care should be taken when removing the top plenum from the lower cabinet so as not to tear the fiberglass insulation. 3. Remove the plenum front panel from the lower cabinet. 4. The fasteners for assembling the unit, the riser blockoffs, and sight baffle (if required) are located in the base of the lower cabinet. The filter is located above the coil. Remove these parts from the unit. Remove the valve package supports. 5. For ease of installation, bend out the tabs that support the top plenum to the lower cabinet (see Figure 5). 6. Place the riser blockoffs over the riser stub-outs (see Figure 4). 7. Remove the appropriate riser and drain knockouts in the lower cabinet (see Figure 5). 8. Slit the fiberglass insulation so that the riser valves can be pushed through and into the unit. 9. Position the lower cabinet to the risers. The horizontal stub-outs should be centered in the opening in the cabinet. This is important to allow for riser expansion and contraction of plus or minus one inch. 10. Solder connections if sweat valves have been supplied. 11. Attach plastic drain hose to drain line. Be sure hose clamp is properly installed. 12. With the unit in the final location, check level to insure proper condensate drainage and operation. 13. Fasten the top panel of the plenum by installing the three sheet metal screws A (see Figure 6). 14. Install the sight baffle (if required) to the top as shown in Figure 6. Unit Installation 15. Place the top plenum on the lower cabinet (see Figure 6). The top plenum can be installed so that the discharge opening is facing to the left, the right, or to the front. Knockouts are provided for additional discharge arrangements. If plenum is to be rotated to the left or right, the thermostat box can be moved to an alternate location by removing the optional cover plate. When the thermostat is moved to the alternate location the cover plate must be insulated and reinstalled in the previous location. Determine the correct discharge before installing the plenum to the lower cabinet. Although the plenum may be rotated 90 in either direction, the thermostat box and heat baffle must always be located above the return air grille on units with electric heat. 16. Fasten the top plenum to the lower cabinet with sheet metal screws (see Figure 6). 17. Before fastening the plenum front panel to the plenum wrap, snap the nylon electrical receptacle into the square hole into the back of the thermostat box (see Figure 7). 18. Attach the plenum front panel to the plenum wrap with sheet metal screws enclosed. 19. The thermostat box has been installed in the plenum front panel in the position that will allow plasterboard to be attached directly to the unit. If the installation requires that the wall be furred out away from the unit, the box can be adjusted out 3 7 8" (98 mm) by removing the four screws A (see Figure 8) and pulling the box out. Align with holes C. Replace screws A. If a dimension other than the 3 7 8" (98 mm) or 3 8" (10 mm) is required, this can be accomplished by using the angle bracket as a template and drilling.149" (4 mm) diameter holes in the box at the desired depth. 20. When the plasterboard or other wall material does not fit flat against the face of the unit, extension sleeves must Figure 3. Unit preparation for field assembly Figure 4. Riser blockoff placement Lower Cabinet Serial Plate Top Front Top Plenum Riser Blockoffs Drain Blockoff Drain Riser Page 3
be furnished by the contractor for both the return and supply air openings. 21. Wire in accordance with local codes or the National Electric Code, whichever is applicable. Provide branch circuit overcurrent protection and disconnect means. The complete system wiring diagram is located on the front access cover. Bring electrical wiring through the side of the cabinet into the wiring box located on the right-hand side of the cabinet (see Figure 7). Two 7 8" (22 mm) diameter knockouts are provided. 22. The return air bulb on the thermostat must be strung through the hole in the back of the thermostat box and down through the hole in the fan deck support angle and attached to the bulb clip below the fan deck (see Figure 7). 23. Rotate the fan wheel by hand to make sure wheel is free. 24. Vent the coils. Vent is accessible from return air opening. 25. If ducts are being added, be sure the resistance is within the limits of the external static pressures shown in the catalog for the particular unit being installed. The ducts should be designed for velocities in accordance with the methods outlined in the ASHRAE Guidebooks. It is recommended that airborne noise be controlled with sound attenuating materials and by installing flexible Figure 5. Riser knockout locations connection between the unit and ductwork. Ductwork should be installed in accordance with NFPA 90A and NFPA 90B. 26. When furring in units, make sure that no screws (other than grille or plaster frame attaching screws) or nails penetrate the unit cabinet. Grille or plaster frame attaching screws should never penetrate the cabinet more than two inches. 27. When installing the grille panel without a plaster frame, use it as a template to drill pilot holes into the wall or unit for attaching screws (see Figure 11). When a plaster frame is ordered, it should be attached on the opening over the top of the plasterboard. Use the plaster frame as a template to drill pilot holes into the wall or unit for the attaching screws (see Figure 12). In order for the grille panel to fit the plaster frame properly, the plaster frame must be mounted with the corners square. When the plaster frame has been mounted to the unit, attach the two retaining clips (supplied with the plastic frame) to the plaster frame adjacent to the lower attaching screws (see Figure 13). Figure 6. Installation of top plenum A Plenum Wrap Front Access Cover Optional Sight Baffle Riser Knockouts (All Sides) Plenum/ Front Drain Knockout (All Sides) Alternate Thermostat Location (For Hydronic Units Only) Front Access Riser Knockouts (All Sides) Support Tabs Drain Knockout (All Sides) Page 4
Figure 7. Thermostat installation Receptacle Quick-Connect Plug Unit Mounted Thermostat Capillary Tube For Return Air Bulb Return Air Bulb B C 4 1 2" (114 mm) 14 15 16" (379 mm) 20" (508 mm) 20" (508 mm) 5" (127 mm) 2" (51 mm) 1" (25 mm) 3/8" + (10 mm +) Discharge Opening Thermostat Box B Field Wiring Box Coil 11/32" (9 mm) 2" (51 mm) Access 7/8" (22 mm) Knockouts B 86" (2184 mm) 104 (2641.6 mm) 60" (1524 mm) 42-7/8" (1089 mm) 35" (889 mm) Drain Pan & Fan Deck C Drain Line 19" (483 mm) 1" (25 mm) Return Air Opening Page 5
Figure 8. Thermostat electrical box 3/8" (10 mm) 3-7/8" (98mm) A (Both Sides) Figure 9. Field wiring box for units with line voltage control systems Figure 10. Field wiring for units with low voltage control systems Wiring Box Wiring Box Low Voltage Compartment Terminal Block Terminal Block Wiring Box Cover Pigtails For Field Wiring Wiring Box Cover Pigtails For Field Wiring Page 6
Figure 11. Grille panel without plaster frame, plan view Figure 12. Grille panel with plaster frame, plan view 9/16" (14 mm) 1/2" (13 mm) Wall Plaster Frame Wall Grille 3/8" (10 mm) 1/2" (13 mm) Grille Cabinet 3/8" (10 mm) Cabinet 4 Screws Provided 15/32" (12 mm) Four (4) Screws for attaching the Plaster Frame are provided. Figure 13. Installation of grille panel with plaster frame Wall Wall Retaining Pin Retaining Clip Plaster Frame Grille Retaining Clip Grille 1. After the unit is furred in, but prior to unit start-up, make sure no foreign material remains in the unit, paying particular attention to the drain pan and drain line. Blockage of the drain line will result in water overflow of the drain pan. 2. Open supply and return water service valves. 3. If unit does not have the automatic flow control option, balance water flow rate with hand valve on return line. 4. Replace front access cover (see Figure 5). 5. Put filter into position. 6. Install return air grille. Start-up 7. All windows and doors should be in and closed before starting up the unit. 8. Switch unit to on and check for proper operation of fan, fan speed switch and thermostat. 9. When there is a high amount of moisture in the air, the initial pulldown should be very gradual (high fan speed for maximum airflow with reduced gpm and elevated chilled water temperature for reduced capacity). Outside air supply and toilet exhaust systems should not be operated until the gradual pulldown has been completed. If these steps are taken, the possibility of the unit sweating will be reduced. Page 7
1. Filters must be clean to obtain maximum performance. They should be inspected every three or four months under normal operating conditions and be replaced when necessary. Units should never be run without a filter. 2. In areas where airborne bacteria produce slime in the drain pan, it may be necessary to treat chemically to minimize the problem. Contact your local McQuay representative or one of the many companies dealing with water conditioning. 3. The condensate drain pan can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow. 1. If fan motor service is required on the S03 or the S04, the fan motor can be removed through the return air opening as follows: a. Shut off electrical power to unit. b. Remove return air grille panel. c. Remove front access cover (see Figure 6). d. Disconnect the fan motor leads at the wiring box. e. Remove the bottom half of the fan housing by taking out the two screws on the housing. f. Remove the clips that hold the motor to the motor base. g. Remove the motor. h. Fan wheel is pressed on motor shaft; pull to remove. i. Reverse process to reassemble. 2. If fan motor service is required on the S06 or S08, the fan and motor can be removed through the return air opening as follows: a. Shut off electrical power to unit. b. Remove return air grille panel. c. Remove front access cover (see Figure 6). d. Disconnect the fan motor leads at the wiring box. e. Remove the screws that hold the inlet ring to the fan housing. f. Remove the fan wheel, motor, and inlet ring assembly from the fan housing. g. Loosen fan wheel setscrew. h. Remove the three screws holding the motor to the inlet ring. i. Service can now be performed. j. Reverse process to reassemble. Maintenance Service 4. The fan motor has been oiled at the factory. It is not necessary to oil the first six months when under continuous operation. Oil every six months with one teaspoon or 5 cc per bearing of SAE No. 20 nondetergent oil. Do not overlubricate. 5. The coil must be clean to obtain maximum performance. Check once a year under normal operating conditions and if dirty brush or vacuum clean. Care must be taken not to damage the aluminum fins while cleaning. Caution: Fin edges are sharp. 3. The McQuay electric heat elements, if furnished, are designed with a high limit control set to trip out when the cabinet temperatures reach and excessive temperature and automatically rest when the cabinet temperatures return to normal. If the high limit opens the circuit, the unit is not performing properly and should be checked to find the cause. Some probable causes would not be enough air over the heater due to dirty filter, fan motor not operating, dirty coil, fan wheel loose on the motor shaft, or loose electrical connections. 4. If the electrical heater should require service, it can be done in the following manner: a. Shut off electrical power to the unit. Caution: There may be more than one power source on the unit. b. Remove the return air grille and front access cover. c. Remove the electric heater junction box cover. d. The high limit control can be replaced without removing the element from the unit. It is done by removing the nut on the appropriate terminal post and lifting the defective part out. e. The entire element can be removed by disconnecting the wires form the terminal posts and removing the screws in the back of the junction box that hold the heater to the support bracket. Slide the heater out and replace. f. The electric heater contactor is located in the field wiring box (see Figures 9 and 10). Replacement Parts When writing for service or replacement parts, direct your letter to McQuayService. Always provide a complete description of the service part, part number (if known), plus complete serial and model number of unit involved. AAF-McQuay Incorporated 4900 Technology Park Boulevard, Auburn, NY 13021-9030 USA (315) 253-2771 Printed on recycled paper containing at least 10% post-consumer recycled material.