RoofPak Singlezone Roof Mounted Heating and Cooling Units ... & U1/U2 (Optional) SV5, 6 (Optional) OAT

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  • ©1996 McQuay International

    IM 157-10

    Group:Applied Systems

    Part Number: 321960Y-01

    Date: January 1997

    Installation & Maintenance Data

    RoofPak® Singlezone Roof Mounted Heating and Cooling Units

    RPS/RFS/RCS 018C- 040C

    ®

    ©1997 McQuay International

    L I S T E D ®

    L I S T E D ®C

  • Page 2 / IM 157

    Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Typical Component Locations . . . . . . . . . . . . . . . . . . . 4 Condenser Fan Arrangement . . . . . . . . . . . . . . . . . . . . 4 Refrigeration Circuit Schematic . . . . . . . . . . . . . . . . . . 5 Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control Panel Locations . . . . . . . . . . . . . . . . . . . . . . . . 6 Controls, Settings, and Functions . . . . . . . . . . . . . . . . 9

    Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Roof Curb Assembly and Installation . . . . . . . . . . . . . 13 Post and Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . 16 Rigging and Handling . . . . . . . . . . . . . . . . . . . . . . . . . 16 Interconnecting the RCS and RFS Units . . . . . . . . . . 18 Installing Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installing Duct Static Pressure Sensor Taps . . . . . . . 22 Installing Building Static Pressure Sensor Taps . . . . 23 Condensate Drain Connection . . . . . . . . . . . . . . . . . . 24 Unit Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Damper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cabinet Weatherproofing . . . . . . . . . . . . . . . . . . . . . . 27

    Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Field Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Field Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 30

    Preparing Unit For Operation . . . . . . . . . . . . . . . . . . . . . 31 Relief Damper Tie-down . . . . . . . . . . . . . . . . . . . . . . . 31 Spring Isolated Fans . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Adjustment of Scroll Dampers . . . . . . . . . . . . . . . . . . 32 Adjustment of Supply Fan Thrust Restraints . . . . . . . 32 Adjustment of Seismic Restraints . . . . . . . . . . . . . . . 33 Spring Isolated Compressors . . . . . . . . . . . . . . . . . . . 33 Refrigeration Service Valves . . . . . . . . . . . . . . . . . . . . 33

    Sequences of Operation . . . . . . . . . . . . . . . . . . . . . . . . 34 Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Economizer Operation . . . . . . . . . . . . . . . . . . . . . . . . 34 Mechanical Cooling Operation . . . . . . . . . . . . . . . . . . 35 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

    Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Typical Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . 39 Typical Main Control Circuit (VAV Units) . . . . . . . . . . 41 Typical Main Control Circuit (CAV-ZTC Units) . . . . . . 42

    Table of Contents

    Typical Main Control Circuit (CAV-DTC Units) . . . . . . 43 Typical Actuator Control Circuit . . . . . . . . . . . . . . . . . 44 Typical Supply/Return Fan Control Circuit . . . . . . . . 44 Typical Condenser Control Circuit . . . . . . . . . . . . . . . 45

    (1-Compressor/3-Stage) Typical Condenser Control Circuit . . . . . . . . . . . . . . . 46

    (2-Compressor/4-Stage) Typical Gas Furnace Control Circuit . . . . . . . . . . . . . 47

    (Modulating Burner, Mixed Air Intake) Typical Electric Heat Control Circuit (Multistage) . . . 48

    Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Enthalpy Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Part Winding Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Phase Voltage Monitor . . . . . . . . . . . . . . . . . . . . . . . . 49 Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Remote Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . 51 External Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Mixed Air Temperature Alarm . . . . . . . . . . . . . . . . . . . 52 Duct High Pressure Limit . . . . . . . . . . . . . . . . . . . . . . 52 Variable Inlet Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Convenience Receptacle/Section Lights . . . . . . . . . . 53

    Check, Test and Start Procedures . . . . . . . . . . . . . . . . . 54 Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Fan Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Economizer Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Compressor Start-up . . . . . . . . . . . . . . . . . . . . . . . . . 55 Heating System Start-up . . . . . . . . . . . . . . . . . . . . . . 57 Air Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Final Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . 60

    Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . 65 Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Supply Fan Wheel-to-Funnel Alignment . . . . . . . . . . 67 Winterizing Winter Coils . . . . . . . . . . . . . . . . . . . . . . . 67

    Service and Warranty Procedure . . . . . . . . . . . . . . . . . . 67 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 In-Warranty Return Material Procedure . . . . . . . . . . . 67 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

    Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

    Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. Caution: Sharp edges and coil surfaces are a potential injury hazard. Avoid contact with them.

  • IM 157 / Page 3

    Introduction This manual provides general information about the “C” vintage McQuay RoofPak applied rooftop unit, models RPS, RFS and RCS. 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 Bulletin No. IM 684 or 685.

    The MicroTech applied rooftop unit controller is available on “C” vintage applied rooftop units. For a detailed descrip- tion of the MicroTech components, input/output configura- tions, field wiring options and requirements, and service procedures, refer to Bulletin No. 483, “MicroTech Applied

    Rooftop Unit Controller.” For a description of operation and information on using and programming the MicroTech unit controller, refer to the appropriate operation manual (see Table 1).

    Table 1. Applied rooftop unit operation manual literature

    ROOFTOP UNIT OPERATION MANUAL CONTROL CONFIGURATION BULLETIN NO.

    Variable Air Volume (VAV) OM 108

    Constant Air Volume, Zone Temperature Control (CAV-ZTC) OM 109

    Constant Air Volume, Discharge Temperature Control (CAV-DTC) OM 110

    RoofPak

    Unit Configuration P = Heating, Mechanical Cooling F = Heating, Future Mechanical Cooling C = Condensing Section Only

    Singlezone Unit

    Nominal Capacity (Tons) RPS, RFS, RCS: 018, 020, 025, 030, 036, 040

    Nomenclature

    R P S - 030 C E

    Heat Medium A = Natural Gas E = Electric F = Fuel Oil S = Steam W = Hot Water Y = None (Cooling Only)

    Design Vintage

    Unit Description

    RPS

    RCS

    ▲RFS▲

  • Page 4 / IM 157

    Typical Component Locations Figure 1 shows a typical RPS unit with the location of the major components and also lists some major dimensions. These figures are for reference only. See the certified submittals for actual specific dimensions.

    Figure 1. Typical component locations

    Power & Control Entrances Outside & Return Air Dampers

    Bottom Return Air Opening Bottom Discharge Air Opening

    94.0" (2388 mm)

    Exhaust Hood

    Air Cooled CondenserHeat Section (Natural Gas, Oil, Steam, Hot Water, Electric)

    Outside Air Louvers

    Return Air Fan

    Supply Air Fan

    Evaporator Coil

    Filter Section

    Discharge Plenum (Main Control Panel)

    55.5" (1410 mm)

    Figure 2 shows the condenser fan numberi