RoofPak Singlezone Roof Mounted Heating and Cooling .RoofPakâ„¢ Singlezone Roof Mounted Heating and

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  • Installation and Maintenance Manual IM-791

    Group: Applied Systems

    Part Number: IM-791

    Date: April 2004

    RoofPak Singlezone Roof Mounted Heating and Cooling Units with Evaporative CondenserRPE/RDE 076C-150C

    2004 McQuay International

    IM-791 Page 1

  • Table of ContentsIntroduction ......................................................................... 3

    Unit Nameplate .............................................................3Gas Burner Nameplate ................................................. 3Hazard Identification Information ............................... 3Nomenclature ............................................................... 3Unit Description ........................................................... 4Condenser Fan Arrangement ........................................5Refrigerant Circuit Schematic ..................................... 5Refrigeration Piping .....................................................6Spray System Plumbing ............................................... 9Bleed Off and Water Consumption ............................10Control Locations ...................................................... 10Control Panel Locations .............................................12Walk-in Service Compartment .................................. 16Controls, Settings, and Functions ...............................17

    Mechanical Installation ..................................................... 19Receiving Inspection .................................................. 19Unit Clearances .......................................................... 19Ventilation Clearance .................................................20Overhead clearance .................................................... 20Roof Curb Assembly and Installation ........................ 21Post and Rail Mounting ..............................................24Rigging and Handling .................................................24Reassembly of Split Units .......................................... 26RPE/RDE Factory Split at Fan ...................................26Condensate Drain Connection ....................................28Unit Piping ................................................................. 28Steam Coil Piping ...................................................... 29Steam Piping Recommendations ............................... 29Steam Trap Recommendations .................................. 30Damper Assemblies ................................................... 31Cabinet Weatherproofing ........................................... 32Installing Ductwork ................................................... 32Installing Duct Static Pressure Sensor Taps .............. 33

    Electrical Installation ........................................................ 35Field Power Wiring .................................................... 35Field Control Wiring .................................................. 36

    Preparing Unit for Operation ............................................ 37Relief Damper Tie-Down .......................................... 37Spring Isolated Fans ................................................... 37Adjustment of Seismic Restraints ...............................39Spring Isolated Compressors ..................................... 39

    Sequences of Operation .................................................... 40Power-up .................................................................... 40Fan Operation ............................................................ 40Economizer Operation ............................................... 40Mechanical Cooling Operation ...................................44Heating ....................................................................... 45

    Wiring Diagrams ............................................................... 46Wiring Diagrams Legend ........................................... 46 Typical Control Schematic: Discharge Air Control (DAC) ....................................48Typical Control Schematic: Zone or Space Comfort Control (SCC) ......................50Typical Output Schematic: Actuator Control .............52Typical Output Schematic: Auxiliary Fan Start/Stop Control ............................... 53Typical Output Schematic: Auxiliary VFD Control ..............................................54

    Typical Power Circuit Wiring - 4 Compressor - VFD .................................................. 55Typical Condensing Unit Control - MicroTech II - 4 Compressor ..................................... 56Typical Supply / Return Fan Control Wiring (No Controls) .............................................................. 58Typical Gas Furnace Control Circuit - Modulating Burner - Mixed Air Intake ...................... 59Vestibule Lights, Receptacle and Options ................. 60

    Unit Options .......................................................................61Enthalpy Control ........................................................61Hot Gas Bypass .......................................................... 63External Time Clock .................................................. 64Smoke Detectors .........................................................64Freeze Protection ........................................................64Low Airflow Alarm ....................................................64Duct High Pressure Limit ...........................................64Condensing Unit Variable Frequency Drive Operation ..........................................................64Variable Frequency Drive Operation ......................... 65Convenience Receptacle/Section Lights ....................65DesignFlow Outdoor Air Damper Option ..............65Propeller Exhaust Fan Option .................................... 67Propeller Exhaust Fan Control ................................... 70

    Check, Test, and Start Procedures .....................................72Before Start-up ...........................................................72Power-up..................................................................... 72Fan Start-up ................................................................72Economizer Start-up ...................................................73Evaporative Condenser Start-up .................................73Compressor Start-up ...................................................73Oil Pressure ................................................................75Heating System Start-up .............................................75Air Balancing ..............................................................75Sheave Alignment ...................................................... 76Drive Belt Adjustment ............................................... 77Mounting and Adjusting Motor Sheaves ....................78Rooftop Equipment Warranty Registration Form: ..... 81

    Final Control Settings ........................................................85Maintenance .......................................................................89

    Planned Maintenance ..................................................89Sump Cleaning ...........................................................89Unit Storage ................................................................90Gas Furnace ................................................................90Bearing Lubrication ....................................................90Setscrews ....................................................................91Supply Fan Wheel-to-Funnel Alignment ...................92Refrigerant Charge .....................................................93Replacing Failed Refrigerant Sensors or Switches .................................................................93Winterizing Water Coils .............................................93Evaporative Condenser Section ..................................94

    Replacement Parts List ......................................................96Limited Product Warranty .................................................97Service and Warranty Procedure .......................................97

    Replacement Parts ......................................................97Compressor .................................................................97In-Warranty Return Material Procedure .....................97

    Page 2 IM-791

  • IntroductionThis manual provides general information about the C vin-tage McQuay RoofPak applied rooftop unit, models RDE and RPE. In addition to an overall description of the unit, it includes mechanical and electrical installation procedures, commissioning procedures, sequence of operation informa-tion, and maintenance instructions. For further information on the optional forced draft gas-fired furnace, refer to Bulle-tin No. IM 684 or IM 685.

    The MicroTech II applied rooftop unit controller is available on C vintage applied rooftop units. For a detailed descrip-tion of the MicroTech II components, input/output configura-tions, field wiring options and requirements, and service procedures, refer to IM696 for a description of operation and information on using and programming the MicroTech II unit controller, refer to the appropriate operation manual (See Table 1).

    For a description of operation and information on using the keypad to view data and set parameters, refer to the appropri-ate program-specific operation manual. (See Table 1).

    Table 1: Program Specific Rooftop Unit Operation Literature

    Unit NameplateThe unit nameplate is located on the outside lower right cor-ner on the main control box door. It includes the unit model number, serial number, unit part number, electrical character-istics, and refrigerant charge.

    Gas Burner NameplateOn units which include gas heat, the nameplate is located on the lower right corner on the main control box door. It includ

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