C05_Parker_Dam_s_Current_Mainstream_mlr-176X122X2_0-HD_Installation_and_Maintenance_Manual_-_Attach_005.pdf

Installation and Maintenance Manual MLR Indoor Air Handler

© 2010 MAINSTREAM FLUID AND AIR, LLC

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Contents Introduction

General Information Receiving and Handling Unit Storage Nomenclature

Mechanical Installation Service Clearances Rigging Unit Leveling Assembling Sections

External Section-to-Section Mounting Horizontal Airflow Section Mounting Vertical Inverted Airflow Section Mounting . . . 6 Extended Coil Section Mounting Internal Section-to-Section Mounting Ceiling Hung

Panels, Frame Channels, and Doors Panel Removal Frame Channel Removal Fan Section Doors Injected-Foam Insulated Panels

Field Mounting Junction Boxes and Other Compo-nents Face and Bypass Section Mounting

Bypass Into a Vertical Fan Section External Face and Bypass Duct Assembly (Sizes 040 to 090)

Multizone Assembly Multizone Damper Assembly

Duct Connections Multizone Damper Adjustment Multizone, Mixing Box and Economizer Damper Torque Requirements

Mounting Actuators Face Bypass Damper Torque Requirements 15

Piping and Coils Water Cooling Coils Direct Expansion Coils Steam Coils Water Heating Coils

Drain Pan Traps Internal Isolation Assembly Adjustment

Electrical Installation Wiring Control Wiring

Operation Startup Checks Before Starting the Unit Fan Startup After 48 Hours of Operation Fan Wheel Alignment Operating Limits Fan Vibration Levels

Vibration Causes Maintenance

Periodic Maintenance Ball Bearing Lubrication Fan Drive Adjustments

VM/VP Variable Pitch Key Type Sheaves . . 29 LVP Variable Speed Sheaves MVP Variable Speed Sheaves Fan Drive Belt

Front Load Filter Option Filter Gauges Coils

Winterizing Water Coils Removing and Replacing Components

Removing a Side or Top Panel Removing a Frame Channel Removing the Fan Section Removing and Replacing the Coil

Parts Replacement Parts

Service and Warranty Procedure Warranty Warranty Return Material Procedure

Check, Test, and Start Procedure Form Quality Assurance Survey Report or

Introduction

IntroductionGeneral Information MLR Indoor air handlers are not designed to be weather resistant.

Do not install them outdoors.

The system design and installation must follow accepted industry practice as described in the ASHRAE Handbook, the National Electric Code, and other applicable standards. This equipment must be installed in accordance with regulations of authorities having jurisdiction and all applicable codes.

Installation and maintenance must be performed by qualified personnel familiar with applicable codes and regulations and experienced with this type of equipment. Sheet metal parts, self-tapping screws, clips, and such items inherently have sharp edges; the installer should exercise caution.

Receiving and Handling 1 Carefully check items against the bills of lading to verify all crates and cartons have been received. Carefully inspect all units for shipping damage. Report damage immediately to the carrier and file a claim.

2 MLR Indoor air handler units are constructed of galvanized painted steel and are inspected thoroughly before leaving the factory. Take care during installation to prevent damage to units.

3 Take special care when handling the blower section. All fans are dynamically balanced before leaving the factory.

Rough handling can cause misalignment or a damaged bearings or shaft. Carefully inspect fans and shaft before unit installation to verify this has not happened.

4 Handle the zone damper of the multi-zone units with special care. Zone dampers are set and inspected before leaving the factory, but should be checked on arrival to the job to verify the bell arm and connecting rod set screws did not become loose in shipment.

Note: Screws, bolts, etc., for assembling sections are supplied in a bag attached to each section. All necessary gasketing is applied in the factory for section-to-section mounting.

Unit Storage Store unit on a level surface. If air handling units are stored for any period of time, periodically rotate the fan wheel to prevent permanent distortion of drive components. In addition, grease may settle in the lower part of the bearing, which can lead to oxidation on the upper portion of the bearing surface. Keep the fan bearings lubricated.

Store units indoors in a clean, dry environment on a level surface. Moisture, debris, and minerals can cause permanent damage to the cabinet and components. Do not allow coverings to trap moisture on the galvanized surface.

Nomenclature

CAUTION

Sharp edges and coil surfaces are a potential injury hazard.

Avoid contact with them.

ATTENTION

Les bords tranchants et les surfaces des bobines sont un risque de blessure. Ne les touchez pas.

MLR - 60 X 54 X 2 - HD

MLR

SERIES

CONFIGURATION

HD = HORIZONTAL DRAW-THRU

VD = VERTICAL DRAW-THRU

UNIT OVERALL

WIDTH IN INCHES

HB = HORIZONTAL BLOW-THRU

SD = STACKED DRAW-THRU

XV = HEAT RECOVERY, STACKED

UNIT OVERALL

HEIGHT IN INCHES

XH = HEAT RECOVERY, SIDE-BY-SIDE

2 = 2" DOUBLE WALL

Mechanical Installation

Mechanical InstallationService Clearances In addition to providing adequate space around the unit for piping coils and drains, access to at least one side of the unit is always required to allow for regular service and routine maintenance, which includes filter replacement, drain pan inspection and cleaning, fan bearing lubrication, and belt adjustment. Provide sufficient space—at least equal to the length of the coil—on the side of the unit for shaft removal and coil removal. Space, at least equal to the length of the side coil, is required for coil removal. Space, at least equal to the fin height, is required for top coil removal. See Figure 1 for servicing space requirements.

For routine maintenance purposes, access normally is obtained through the access doors or by removing panels. Fan and filter sections are always provided with a service door on one side of the unit. If requested, doors can be provided on both sides of the unit. Optional service doors are available for most section types and are provided based on customer request.

If component replacement is required, the top panel also can be removed. If necessary, the unit can be disassembled.

Maintain at least 54" of clearance in front of electrical power devices (starters, VFDs, disconnect switches and combination devices). Electrical power devices that are mounted on the side of the unit typically are up to 12" deep (Figure 2).

Figure 1: Servicing Space Requirements

Figure 2: Service Clearance for Electrical Power Devices

Rigging MLR Indoor air handlers ship as separate sections, completely assembled, or in modules of assembled sections. The unit must be rigged as it ships from the factory. Do not rig units after assembly. When a unit is provided with a factory-installed base rail, it can be lifted using the 2" diameter lifting holes located in the corners of each shipping section (Figure 3). If a unit does not have a base rail, rig it using straps or a sling. Fasten the strapping under the skid that ships with the section (Figure 4).

To prevent damage to the unit cabinetry, use spreader bars.

Position spreader bars to prevent cables from rubbing the frame or panels. Before hoisting into position, test lift for stability and balance. Avoid twisting or uneven lifting of the unit.

Figure 3: Units on Base Rails

Figure 4: Units on Skids

Fan sections greater than 108" wide that are stacked on another section are constructed with internal fan support frames that have integral lifting brackets (Figure 5). After the fan section is placed in position, remove and discard the lifting brackets.

Install the small panels provided to complete the unit cabinet areas where the lifting brackets were located.

Figure 5: Large Fan Sections Stacked on Top of a Lower Section

Unit Leveling Place the equipment on a flat and level surface. Where the surface irregularities could cause the equipment to distort, use a shim so the base of the unit is a straight line. Uneven or distorted sections cause misfit or binding of the doors and panels and improper draining of drain pans.

Units that are over 108" wide must rest on a flat surface for the entire width of the base rails or must be shimmed at one or more points along the length of the rails to prevent distortion or sagging of the support rails (Figure 6).

Figure 6: Leveling the Unit

Assembling Sections

External Section-to-Section Mounting MLR Indoor air handling units can ship fully assembled or as separate shipping sections. Rig units that require field assembly of shipping sections into position first. Shipping sections are provided with a connection splice joint attached on the leaving air side of the shipping section. The splice joint is insulated and provides an air-tight seal between two sections once they are assembled together. If the splice joint was bent during shipping or rigging, restore it to its original position.

(Figure 10, page 7).

Horizontal Airflow Section Mounting 5 Rig the unit into position and lineup shipping sections in the direction of air flow. Pull sections together to fasten.

Use a furniture clamp or straps and a ratchet to help pull the sections together securely (Figure 7).

6 If the unit has a factory-installed base rail, first fasten base rails together using the 3/8"-16 × 5" bolts located in the splice kit provided with the unit.

a To fasten two shipping sections together, four bolts are needed (two on each side of the unit). The bolts are run from one base rail into the other and fastened with a nut. Complete each section bottom and top before attaching additional sections.

7 If no base rail is provided, fasten the unit in the same manner on the bottom and top frame channels.

8 Once the sections are positioned together, remove the fastener in each of the channel corners (on the mating edges in the channel piece).

9 Place a flat section joining plate (found in the splice kit) over the two coned holes in the channels, so that the plate spans the two sections.

10 Replace the fasteners in their original position, through the joining plate.

Figure 7: Horizontal Joining Sections

Vertical Inverted Airflow Section Mounting For vertical or inverted arrangements, before lifting any top mounting sections into place, rig into place and fasten together the bottom tier of sections. Once bottom level sections are in place and secured, lift stacked components and fasten using the following procedure:

Note: See Face and Bypass Section Mounting‚ page 10 for the exception to this procedure.

1 The vertical/inverted section has a splice joint extending out the top of the bottom joining section. Lower the section that is to be positioned over the opening over the splice joint to seal the connection between the two sections.

2 The two sections are fastened together at the four bottom corners of the mating edge. To fasten the corners located on the end of the unit (where bottom section and top section walls are flush with each other), remove the flat head fasteners in the corners of both sections.

3 Cover the coned holes with a flat joining plate and replace the flat head fasteners in the holes to secure the joining plate to both sections (Figure 8).

4 When one section is deeper than the other, secure the two sections using an L-shaped joining plate. To secure the L-shaped bracket, remove the flat head fastener from the corner, position the bracket over the hole, and replace the flathead fastener with a 5/16"-18 × 1" bolt. Once the bolt is in place, secure the bracket to the adjoining section with a 1/4 × 1" drill screw. Repeat the same procedure on both corners of the unit (Figure 8).

Figure 8: Vertical/Inverted Joining Sections ed Extended Coil Section Mounting The extended coil section is 6" wider than all other sections of the same unit size. The extension is always located on the coil connection side of the unit. Because the extended coil section is wider than other sections, it always ships as a separate shipping section, and must be joined to other sections in the field. To join an extended coil section to other components, first follow the Horizontal Airflow Section Mounting‚ page 6 steps to secure the opposite connection side. To fasten the connection side, use the following procedure:

1 If the unit has a factory-installed base rail, the extended coil section base rail is also 6" wider than the adjoining base rail. Extended coil section base rails on the connection side are fastened together using the 3/8"-16 by 3" bolts located in splice kit provided with the unit (Figure 9).

2 If no base rail is provided, the section is fastened in the same manner on the bottom and top. Once the sections are positioned together, remove the fastener in the corner of the channel piece of the section mating to the extended coil section (Figure 9).

3 Place an L-shaped section joining plate (located in the splice kit) over the coned hole in the channel.

4 Replace the flat head fastener originally used in the corner with a 5/16"-18 1" bolt and fasten it through the L-shaped joining plate.

5 Position the L-shaped joining plate so it butts up against the extended coil section frame channel. To secure the plate to the extended coil section, run two 1/4" × 1" drill screws through the joining plate and into the frame channel.

Figure 9: Extended Coil Section Joining

Internal Section-to-Section Mounting If desired, shipping sections can be fastened together internally. To fasten internally, run field-provided #10 sheet metal screws or drill screws (4" long maximum) through the interior frame channel of one unit into the splice joint of the neighboring section.

The section-to-section splice joint is always provided on the leaving air side of a shipping section and seals against the frame channel on the entering-air side of the adjoining section.

Align the splice joint to seat into the mating gasket to provide an air seal. If the splice joint was bent during shipping or rigging, restore it to its original position (Figure 10).

Figure 10: Internal Fastening

Ceiling Hung When a unit is ceiling hung, support it with a base rail, angle iron, or channel. TheMLR Indoor air handler is not designed to be suspend from the top of the unit. Before hanging, rig and completely assemble the unit. See Assembling Sections‚ page 6.

Ceiling Hung Using Base Rail The optional base rail provided by the factory has 5/8" diameter holes in each corner to run hanger rods through. To properly support the unit and maintain unit integrity, support each shipping section with hanger rods in each corner (Figure 11).

Figure 11: Ceiling Suspended with Base Rail

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Ceiling Hung Using Angle Iron Channel Install field-provided angle iron or channels per SMACNA guidelines. When a unit is unitized (ships in one piece), channel support each component under the unit width (Figure 12).

When a unit is sectionalized (ships in multiple sections), channel support each component under the unit width and provide support under the full length of the unit base (Figure 13). Locate hanger rods so they do not interfere with access into the unit.

Ceiling suspension using the unit base rails is limited to unit cabinet widths less than 108". Support units with cabinets 108" wide and greater with structural members designed to support the unit at the ends and at intermediate points along the base rails.

Figure 12: Ceiling Suspended w/o Base Rail—Unitized Construction

Figure 13: Ceiling Suspended w/o Base Rail—Modular Construction

Panels, Frame Channels, and Doors

Panel Removal To remove a side or top panel, remove the flat head Torx 30 fasteners along the sides of the panel. Lift off the panel after removing all fasteners.

Frame Channel Removal Frame channels that run the length of the unit along the top can be removed to allow access to both the side and top of the unit.

To remove the frame channel, first remove the side panel(s).

Once the side panel is off, remove the flat head Torx 30 fasteners in the corner of the frame channels. Then pull the frame channel out the side. Remove any panel screws that are within one inch of the of the frame since they are engaged into the gasketed flange of the frame (Figure 14).

Figure 14: Removing Panel Screws

NOTE

The supporting angle iron must fully support the 2" frame channel at each section joint.

Remove panel to remove frame

Remove any panel screws that engage frame

Fan Section Doors Note: Opening fan section doors requires using a 1/2" socket wrench (Figure 15), which satisfies ANSI standards and other codes that require the “use of tools” to access compartments containing moving parts or electrical wiring.

1 Remove padlock if one is present.

2 Insert 1/2" socket into cup and rotate 1/4 turn clockwise as shown in Figure 15. If the cup and handle are on the left side of the door, rotate 1/4 turn counterclockwise.

3 Rotate the door handle 1/4 turn clockwise and then 1/4 turn counterclockwise to release any internal pressure or vacuum and open the door. If the cup and handle are on the left side of the door, rotate the door handle 1/4 turn counterclockwise and then 1/4 turn clockwise.

4 To prevent air leakage, tighten the door panels by adjusting the jam nuts.

Figure 15: Opening Fan Section Door

CAUTION

Sharp edges and coil surfaces are a potential injury hazard.

Avoid contact with them.

ATTENTION

Les bords tranchants et les surfaces des bobines sont un risque de blessure. Ne les touchez pas.

CAUTION

DO NOT attempt to rotate the cup.

Damage to the unit will occur.

ATTENTION

NE PAS tenter de faire tourner la cuvette (cup).

Ceci va dendomagger l’unité.

OPEN

View from inside door

Jam Nuts

Do Not Rotate Cup

Injected-Foam Insulated Panels MLR Indoor air handlers are furnished with double-wall, injected-foam insulated panels. Foam panels are stronger, more rigid, and lighter than panels with fiberglass insulation. The insulation R-value is improved to 13. However, foam insulation can burn when exposed to flame or other ignition sources and release toxic fumes. Take care in cutting and sealing all field-cut openings in these panels.

Panel Cutting Procedure 1 Determine the number and location of holes required for electrical conduit, piping, and control wiring as follows (also refer to Figure 16):

a Check that adequate space is available inside the unit for conduit or pipe routing.

b Do not locate holes in a panel that provides access to key maintenance components such as filters and fan assemblies.

c Do not locate where the conduit or piping blocks airflow or obstructs hinged access doors.

2 Once a proper location is determined, drill a small pilot hole completely through the panel. Then use a sharp hole saw or a saber saw and cut from each side of the panel.

3 Seal the double-wall panel on each side with an industrial/commercial grade silicone sealant or duct seal compound. It is extremely important to seal each panel hole or penetration securely so that it is airtight, watertight, and that there is no exposed foam insulation.

Figure 16: Cutting/Sealing Injected-Foam Insulated panels

Field Mounting Junction Boxes and Other Components For field mounting 4" × 4" or smaller junction boxes to the standard panel exterior, use a minimum quantity of four, 3/16" diameter pop rivets. Do NOT use self-tapping drill screws.

They will not tighten nor secure properly and panel damage can occur.

If larger, heavier components require mounting on unit panels, use through-bolts with flat washers through both outer and inner panels. To maintain panel integrity, seal both ends with an industrial/commercial grade silicone sealant or duct seal compound.

The unit frame channel is another excellent location for securing heavier components; self-tapping screws are not acceptable. Ensure that the location permits the full operation of all access doors and panels and does not interfere with other vital components.

Face and Bypass Section Mounting Internal face and bypass, and external face and bypass for sizes 003 to 035 are mounted together using the instructions for horizontal components and do not require additional instruction.

For all size units that bypass directly into a vertical fan section and for sizes 040 to 090 with external face and bypass, use the following instructions.

Bypass Into a Vertical Fan Section Vertical coil sections and the top mounted fan section always ship separately and must be mounted together at the job site.

The vertical coil section and the bypass duct each has a joining collar mounted on the leaving air side of the section and duct, respectively (Figure 17). The mounting collar fits into the side (bypass) and bottom (vertical coil section) openings in the fan section. To correctly position the collars in the fan openings, WARNING

Flame and smoke can cause equipment damage, severe personal injury, or death.

Before operating unit, seal all piping and wiring holes on both inner and outer panels with an industrial grade silicone sealant or duct seal compound. Do not use a cutting torch or expose panel to fire. Panel damage can occur.

WARNING

La fumée et les flammes peuvent endommager le matériel et causesr des blessures graves ou la mort.

Avant d’utiliser le dispositif, obturer tous les trous de passage de tubulures et de fils ménagés dans les panneaux intérieurs et extérieurs au moyen d’une pâte à base de silicone ou d’un mastic d’étanchéite â conduits de qualité industrielle.

Ne pas se servir d’un chalumeau coupeur ni exposer les pannequx à une flamme nue pour ne pas risquer de les endommager.

Cut hole from both sides of panel

Seal completely with silicone sealant or duct seal compound

Prop 65—Substances in fuel or from fuel combustion can cause personal injury or death, and are known to the State of California to cause cancer, birth defects or other reproductive harm.

assemble the fan and coil section first. Use the steps below for assembly.

1 Place the vertical coil section in position. If an access section is positioned downstream from the coil section and not already assembled to the coil section, secure the two sections together.

2 Lift the fan section on top of the vertical coil section, taking care to line up the joining collar in the bottom of the fan section.

3 For sizes 003 to 035, the bypass duct is integral to the unit construction and does not require attachment to the bypass section. For sizes 040 to 090, position and assemble the bypass duct to the bypass section before joining to the fan.

4 Once the fan is positioned on top of the vertical coil section and the bypass duct and bypass section are assembled, position the two assemblies and line up the joining collars with the openings in the fan and vertical coil section.

5 Once the sections are lined up and in position, secure the unit together by fastening joining plates to the unit.

Figure 17: Assembly of Fan Coil Sections

External Face and Bypass Duct Assembly (Sizes 040 to 090) When unit sizes 040 to 090 are ordered with external face and bypass, the bypass duct ships separately and must be attached to the unit in the field. The joining of the bypass duct to the unit must be done after the unit is assembled. Also, if the bypass duct is over 90" long, the duct does not ship in one piece and must be field assembled. The field assembly of the bypass duct to the unit requires the following steps (also refer to Figure 18, page 11).

1 Position the unit shipping sections together and assemble in the equipment room.

2 After the unit is assembled, lift the duct into position over the unit. Joining collars are shipped factory assembled to the unit and duct. There is a joining collar located in the top of the bypass opening and in the leaving air side of the bypass duct. These joining collars are used to provide air seals. Line up the duct with the top openings in the unit.

3 If the bypass duct is longer than 90", the duct ships in more than one piece and must be field assembled. Place the piece of duct that has the joining collar on the bottom on top of the unit first. Once it is in place, position the other piece of duct. Take care to fit the splice collar into the first piece of duct and then lower the other end into the bypass opening.

4 Once the duct is positioned correctly, fasten the duct pieces together with the joining plate provided. To do this, remove the fasteners in the corners of the duct assemblies, place the plate over the holes in the corners, and then replace the fasteners (Figure 7, page 6).

Figure 18: Assembly of Bypass Duct to Unit

Joining collar

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2 � � � � � � � 1 �

Multizone Assembly The multizone section may ship completely assembled or it may ship in numerous pieces. Whether the section ships in a single piece or multiple pieces depends on customer requirements and the unit size. When a multizone section is over 90" high or 90" wide, split it into sections for shipping.

The unit may ship in 1, 2, 3, 4, or 5 separate pieces. Typically, the multizone damper assembly ships separately (see Multizone Damper Assembly in the next column and Figure 20) and must be attached at the job site. Attach the damper after the other components are assembled. Use the instructions below for assembling the multizone section (also refer to Figure 19, page 13).

1 If the diffuser and the cold deck section ship separately, join them together first. The joining collar mounted in the diffuser fits into the entering air side of the coil section. Line up the two sections and fasten together.

2 Once the diffuser and cold deck sections are joined, lift the hot deck and bypass sections in place on top of the diffuser/cold deck section. If possible, assemble the hot deck and bypass section (if there is one) together before lifting on top. There always is a joining collar in the diffuser. The joining collar provides the seal between the sections joints. It is important to line up and fit the collar in the hot deck and bypass section. For vertical applications, the cold deck also has a joining collar in the discharge opening. This collar fits in the bottom of the vertical bypass section.

3 After the components in the multizone are fitted together, fasten the joining plates to the corners in the unit exterior.

4 If a damper was ordered, assemble it to the section (see Multizone Damper Assembly in the next column and Figure 20, page 13).

Note: Verify that the joining collars are aligned to seat into the gasket. Straighten any collars distorted from shipping or from rigging.

Multizone Damper Assembly When a multizone unit is ordered with dampers, depending on the multizone configuration and size, the damper assembly may ship separately (all horizontal and units with a total height over 90").

When the dampers are not factory assembled to the unit, they ship to the job site on a skid. An assembly kit with screws and an instruction drawing are included with the damper for field assembly to the unit.

To assemble:

1 First remove the side plate that encloses insulation from both sides of the damper assembly.

2 Lift the damper assembly into position (Figure 20, page 13).

3 Fasten the assembly to the frame channels within the multizone openings.

4 Use caulking to seal up the areas around the unit frame channel to prevent any air leakage.

5 After caulking, put the side plates back in place and secure.

Damper shaft extensions are provided on both ends of the damper assembly for actuation. The dampers are linked together by a linkage bar on both ends of the damper. The linkage bar is cut at the time of installation to divide the damper into the required number of zones (refer to Multizone Damper Adjustment‚ page 14).

Figure 19: Multizone Sections Assembly

Figure 20: Multizone Damper Assembly

Cooling coilCooling coilDiffuser

Joining collars

Zone damper assembly

Upper unit—heating (and optional bypass)

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4 $

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Duct Connections Use flexible connectors on the outlet and inlet duct connections of all units. Each zone divider has a W-shaped duct clip. Insert ductwork into this clip (Figure 21).

Figure 21: Duct Connectors

Note: Before connecting to ductwork, refer to Multizone Damper Adjustment below.

Multizone Damper Adjustment The installer must clear the damper assemblies of construction dirt and debris. These materials result in higher torque requirements and may bend or damage damper components.

Before you begin:

1 Verify that dampers are square and operating smoothly before ducting.

2 Install duct access panels on the downstream damper for inspection and maintenance.

If multizone dampers do not close properly, adjust the blades as follows:

1 Loosen set screws in bell arms for all zones.

2 Close all cold deck dampers tightly.

3 Move bell arms so they are at a 45° angle to the vertical center when viewing the zone dampers from the cold deck end of the damper section (Figure 22).

a Two-deck zone dampers—The cold deck closes when the bell arms are 45° from the vertical center. The hot deck closes when the bell arms are 45° clockwise from the vertical center.

b Three-deck zone dampers—The cold deck closes when the bell arms are 45° clockwise from the vertical center. The hot deck closes when the bell arms are 45° counterclockwise from the vertical center.

4 Tighten set screws on bell arms while holding the dampers closed.

5 All zone damper blades should close properly. If one or a few zones do not close completely, repeat the procedure for these zones.

Figure 22: Bell Arms at 45° Angle to Vertical Center

Multizone, Mixing Box and Economizer Damper Torque Requirements On multizone units, the actuator must drive the connection link for proper damper actuation. Do not activate multiple dampers must from the shaft extension opposite the connection link.

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To divide t he dampe r se ction int o mult iple zone s, cu t an d remove suf ficient connecting link to allow adjacent zones to operate independently.

Note: The damper blades on two-deck dampers seal through several degrees of shaft rotation.The damper blades can rotate 360° and do not engage a stop.

The hot deck blades are mounted at a 90° to the cold deck blades. Before installing the zone duct, set up linkages and dampers and adjust. If adjustment is required and access to the blades is restricted, observe the cold deck blade position by removing the cabinet panel on the coil section.

Mounting Actuators The installing contractor is responsible for the mounting of all field-installed actuators. No provisions are made for the location of these actuators due to the number of options and arrangements available and the variety of specific applications.

Typically, actuators are mounted inside the cabinet. Provide proper support for the actuator to avoid excessive stress in the cabinet, linkage, or damper shafts.

Fresh air and return air dampers can be linked together and driven from the same actuator if the dampers are the same size.

If the dampers are different sizes, they must be driven by separate actuators and controlled appropriately. Exhaust dampers are always driven by a separate actuator.

A typical rotary electric actuator can handle up to 40 sq. ft. of damper. For pneumatic actuators, allow 5 in-lb per square foot of damper area.

Face Bypass Damper Torque Requirements Face and bypass dampers may or may not be linked together.

When dampers are placed before a single bank of coils, they always are linked together and require a single actuator. When dampers bypass a stacked or staggered coil, the dampers are not linked and require multiple actuators. Unit sizes 040 to 090 provided with external face and bypass require three actuators.

Other arrangements with stacked or staggered coils require two actuators. A damper shaft extension is provided.

Normally, the shaft extension is located on the drive side of the unit, but it can be moved to the other side.

Face and bypass dampers have a torque requirement of 10 in-lbs per square foot of damper face area.

Piping and Coils When designing and installing piping:

• Follow applicable piping design, sizing, and installation information in ASHRAE handbooks.

• Observe all local codes and industry standards.

• Do not apply undue stress at the connection to coil headers;

always use a backup pipe wrench.

• Support pipework independently of the coils.

Water Cooling Coils

• Water supply, water return, drain, and vent connections extend through the end panel of the coil section. All connections are labeled on the end panel.

• Water supply and water return connections are typically male NPT iron pipe.

• When installing couplings, do not apply undue stress to the connection extending through unit panel. Use a backup pipe wrench to avoid breaking the weld between coil connection and header.

• Follow recommendations of the control manufacturer regarding types, sizing, and installation of controls.

Direct Expansion Coils

• The coil distributor and suction connection extend through the end panel of the coil section.

• Check nozzle in distributor for proper tonnage.

• When a field supplied thermostatic expansion valve is used, it is located outside the unit and connected directly to the distributor. Do not apply heat to the body of the expansion valve.

• The thermostatic expansion valve must be of the external equalizer tube type. Connect the 1/4-inch diameter external equalizer tube provided on the coil to connection on expansion valve.

• Use care when piping the system to see that all joints are tight and all lines are dry and free of foreign material. For

CAUTION

Maximum damper rotation is 70°.

Maximum shaft torque is 205 inches/pound.

Greater rotation or torque can cause equipment damage.

ATTENTION

La rotation maximale des volets est de 70°.

Le couple (torque) maximum de l’arbre est de 205 po/lb.

Une plus grande rotation (ou torque) peut endommager l’équipement.

Steam Coils

Piping (see Figure 23, page 17)

• All steam coils in units are pitched toward return connection.

• Steam supply and steam return connections typically are male NPT iron pipe and are labeled on the end panel of coil section. Connections extend through the coil section end panel.

• When installing couplings, do not apply undue stress to the connection extending through unit panel. Use a backup pipe wrench to avoid breaking the weld between coil connection and header.

• Support piping independently of coils and provide adequate piping flexibility. Stresses resulting from expansion of closely coupled piping can cause serious damage.

• Do not reduce pipe size at the coil return connection. Carry return connection size through the dirt pocket, making the reduction at the branch leading to the trap.

Coils

• Install vacuum breakers on all application to prevent retaining condensate in the coil. Generally, the vacuum breaker is connected between the coil inlet and the return main. The vacuum breaker should be open to the atmosphere, and the trap design should allow venting of large quantities of air.

• Do not drip supply mains through the coil.

• Do not attempt to lift condensate when using modulating or on/off control.

Traps

• Size traps in accordance with the manufacturers’ recommendations. Make sure that the required pressure differential is always available. Do not undersize.

• Use float and thermostatic or bucket traps for low pressure steam. On high pressure steam, use bucket traps. Use thermostatic traps only for air venting.

• Use bucket traps for on/off control only.

• Locate traps at least 12 inches below the coil return connection.

• Multiple coil installation

• Individually trap each coil or group of coils that is con-trolled individually trapped.

• Coils in series—use separate traps for each coil, or bank of coils.

• Coils in parallel—a single trap can be used, but an indi-vidual trap for each coil is preferred.

• Do not attempt to lift condensate when using modulating or on/off control.

• With coils arranged for series airflow, use a separate control on each bank or coil in the direction of airflow.

Valves

• Do not use modulating steam valves on high pressure systems.

• Properly size modulating valves. Do not undersize.

• Freezing conditions (entering air temperatures below 35°F).

• Mainstream strongly recommends 5JA, 8JA, 5RA and 8RA coils.

• Supply 5 psi steam to coils at all times.

• Do not use modulating valves. Provide control by face and bypass dampers.

• Consider using two or three coils in series with two posi-tion steam control valves on the coil or coils that handle 35°F or colder air. Use a modulating valve on the down-stream coil to provide the desired degree of control.

• Thoroughly mix fresh air and return air before it enters the coil. Also, to obtain true air mixture temperatures, properly locate temperature control elements.

• As additional protection against freeze-up, install the trap sufficiently below the coil to provide an adequate hydrostatic head to remove condensate during an inter-ruption in the steam pressure. Estimate three feet for each 1 psi of trap differential required.

• On startup, admit steam to coil ten minutes before admit-ting outdoor air.

• Close fresh air dampers if steam supply pressure falls below the minimum specified.

Figure 23: Piping Arrangements

Check Valve Strainer Gate Valve Control valve modulating two position

Float and thermostatic trap

High Pressure (over 25 psi)

Low Pressure (to 25 psi)

5GA or 8GA coils. Note that the addition of a vacuum brea ker to permit t he co il to drain dur ing shutdown.

5TA, 8TA, or 5HA coils. Conden-sate is lif ted to overh ead ret urn main

5JA or 8JA coil. Installed in series.

Note that e ach coi l mu st have a separate control valve and trap.

5RA, 8R A, o r 5S A c oils. Banked two high, ind ividual trapping of each coil as shown is preferred.

5RA, 8RA, or 5SA coils. Installed

5J, 5G, 8J or 8G coils.

Water Heating Coils

• Water supply and water return connections extend through the end panel of the coil section. All connections are labeled on the end panel.

• Water supply and water return connections are male NPT iron pipe.

• When installing couplings, do not apply undue stress to the connection extending through unit panel. Use a backup pipe wrench to avoid breaking the weld between the coil connection and header.

• Follow recommendations of the control manufacturer regarding types, sizes, and installation of controls.

• Do not use hot water coils with entering air below 40°F.

• If fresh air and return air are to be heated by a hot water coil, carefully design the system to provide thorough mixing before air enters the coil.

• To prepare coils for winter operation, see Winterizing Water Coils‚ page 33.

Drain Pan Traps Run drain lines and traps full size from the drain pan connection. Install drain pan trap to allow condensate to drain freely. On both blow-through and draw-through units, the trap depth and the distance between the trap outlet and the drain pan outlet must be twice the static pressure in the drain pan section under normal operation so the trap remains sealed (Figure 24).

Figure 24: Allow Adequate Distance Between Trap Outlet and Drain Pan Outlet

CAUTION

Improper installation, use, or maintenance of water heating coils can cause equipment damage.

Read and follow instructions carefully.

ATTENTION

Si l’installation, l’utilisation ou l’entretien des serpentins de chauffage à eau sont inadéquats, ceci endommagera l’équipement.

Lire et suivre attentivement les instructions.

Pressure (P) at the drain pan

2P

2P

Internal Isolation Assembly Adjustment On units with internally isolated fan and motor assemblies, the assemblies are secured for shipment.

Before Operating the Unit:

Remove the shipping brackets and tie-down bolts (refer to Figure 26 and Figure 27, page 20) and discard. The shipping brackets located on the opposite drive side of the unit are difficult to access from the drive side of the unit. Either remove them before the unit is assembled, or remove the panel on the opposite drive side to gain access.

The spring isolators under the four corners of the fan and motor assembly are factory adjusted while the fan was not running. With the unit operating at normal cfm and static pressure, all the isolators should be at the same height opening (Table 1 and Table 2). If adjustments are required, loosen the 1/2" cap screw on top of the isolator and turn the adjusting bolt to lower or raise the fan and motor base. Retighten the cap screw when adjustments are completed.

For models 040 through 090, the isolators should be at equal height (6") during fan operation. Center the fan outlet in the outlet panel opening. If adjustment is required, loosen the bolt on top of the isolator assembly (Figure 25). Turn the adjustment nut below the fan frame to lower or raise the fan motor and frame assembly. Retighten the bolt on top of the isolator assembly.

Figure 25: Adjusting Large Spring Mount Assembly Table 1: Motor Beside Fan Spring Mount Adjustments

Spring mount adjustment at rest

Fan discharge position

Top or bottom horz. H

Downblast H

Upblast H

Unit sizes 003 – 035 1 3.75 3.75 4.25 2 4.25 3.75 4.25 3 4.25 3.75 4.25 4 3.75 3.75 4.25

Unit sizes 040 – 090 1 6.00 6.00 6.50 2 6.50 6.00 6.50 3 6.50 6.00 6.50 4 6.00 6.00 6.50

Table 2: Motor Behind Fan Spring Mount Adjustments

Spring mount adjustment at rest

Fan discharge position

Top or bottom horz. H

Downblast H

Upblast H

Unit sizes 003 – 035 1 6.75 6.75 6.75 2 6.75 6.75 6.75 3 6.75 6.75 6.75 4 6.75 6.75 6.75

Unit sizes 040 – 090 1 6.75 6.75 6.75 2 6.75 6.75 6.75 3 6.75 6.75 6.75 4 6.75 6.75 6.75

Adjusting bolt

6"

Figure 26: Removing “Motor Behind” Shipping Brackets Figure 27: Removing “Motor Beside” Shipping Brackets

Unit sizes 006 - 090 Unit sizes 006 - 090

Electrical Installation

Electrical InstallationWiring

• Electrical service to the fan must correspond to the rated voltage on the motor or electrical panel nameplate and conform to the National Electric Code and local restrictions.

• Connect the fan section metal frame to the building electrical ground.

• A door electrical interlock is not provided as standard.

• Thermal motor protection is external to the unit. Unless the unit is provided with a variable frequency drive (VFD) or a unit mounted starter, thermal protection and a disconnect switch provision per electric codes are provided by others.

• When the unit is factory provided with a disconnect switch, starter or a variable frequency drive (VFD), the components are mounted on the outside of the unit cabinet. Factory wiring is provided from the device to the unit internal motor.

• All electrical components must be grounded to the building central ground. Suitable ground wires and/or (bonding) lugs are provided for all motors, disconnect switches, starters, and variable frequency drives. Provide dedicated ground (bonding) copper conductors in accordance with local and national codes.

• For units provided with a motor only or with an external junction box, wire connections are made with suitable wire nuts or connectors for the gauge wires provided.

• For units provided with a disconnect switch or starter, field wiring will be terminated to lugs. Wire size and lug torque requirements are shown on the unit electrical schematic provided in the component print pocket. All power supply wire connections must be torqued as shown.

• When the unit is provided with a VFD only, refer to the VFD manual for wire size and torque requirements.

• When not being serviced, close and secure electrical panel doors to prevent ingress of moisture and airborne contaminants.

Control Wiring

• Access to the VFD is through the fan cabinet access door.

Provide shielded cable only as described in the provided VFD manual. Route wire through the panel (Figure 16 on page 8) so that it does not interfere with an other components or access doors. Do not drill through drip pans or drain pans. Refer to the provided VFD installation manual for detailed control wiring instructions.

DANGER

Capacitor Hazardous Voltage! Failure to disconnect power and discharge capacitors before servicing will result in serious injury or death.

Disconnect all electric power (including remote disconnects) before servicing. Perform lockout/tagout procedures to ensure that power can not be energized. For variable frequency drives, or other energy storing components that have been furnished and mounted by either Mainstream, or by others, refer to the specific manufacturer’s literature for allowable waiting periods for discharge of capacitors. Verify capacitors have been discharged using an appropriate voltmeter.

ADVERTISSEMENT

Voltage De Condesateur À Risquee De Danger! À défaut de débrancher la puissance électrique et de décharger le condensateur avant de faire le service, il peut en résulter des blessures sérieuses et même la mort.

Débranchez toute puissance électrique (incluant les sectionneurs à distance) avant de faire du service. Assurez-vous de procéder au cadenassage et à la pose d’avis assurant que la puissance ne peut être rétablie .

Pour le variateur de fréquence variable ou tout autre composante pouvant accumuler de l’énergie qui auraient été fournis et installés par Mainstream ou autres, se référer à la littérature spécifique du manufacturier donnant les périodes spécifiques d’attente nécessaires pour la décharge du condensateur. Vérifier que le condensateur est totalement déchargé avec les voltmètres appropriés.

CAUTION

Use copper conductors only! Failure to use copper conductors can result in equipment damage.

ATTENTION

Utiliser du fil de cuivre seulement. La non utilisation de fil de cuivre peut causer des dommages à l’équipement.

Operation

OperationStartup Checks When performing startup and service, always take thorough safety precautions. Only trained, experienced personnel should perform these functions.

Before Starting the Unit Before entering fan section, make sure that fan electrical power source is disconnected and locked in the OFF position.

1 Check that the unit is completely and properly installed with ductwork connected.

2 Check that all construction debris is removed and filters are clean.

3 Check that all electrical work is complete and properly terminated.

4 Check that all electrical connections are tight and that the proper voltage is connected. Phase imbalance must not exceed 2%.

5 Do not grease ball bearings on the fan shaft and motor before startup. They are prelubricated.

6 Check tightness of setscrews in bearings and fan wheel(s). If retightening is needed, position the fan wheel(s) per Table 3 or Table 4, page 23. Torque set screws per Table 7, page 24.

7 Check alignment of fan and motor sheaves and belt tension. Adjust if necessary. Check tightness of sheave setscrews and/or capscrews (refer to Table 15, page 30).

8 Leak test the thermal system to verify that connections are tight.

9 Check that the condensate drain is trapped.

10 Rotate the shaft by hand to be sure it is free.

WARNING

ROTATING FAN

Can cause severe injury or death. Before servicing fans, lockout and tag out power.

AVERTISSEMENT

VENTILATEUR EN ROTATION

Peut causer des blessures sévères ou même la mort.

Avant d’effectuer l’entretien des ventilateurs, bloquer et couper la tension.

WARNING

FIRE/ELECTRIC SHOCK HAZARD.

Can cause property damage, personal injury or death.

Wire fan power supply and ground motor frame in accordance with local electric codes.

AVERTISSEMENT

Risques d´incendie et d’électrocution pouvant causer des dommages matériels, des blessures et même la mort.

L’alimentation électrique du moteur du ventilateur de même que la mise à la terre du chàssis du moteur doivent être faits conformément aux codes d’nstallations électriques en vigueur.

WARNING

Fan motor requires overload protection.

Failure to provide motor overload protection can result in fire, property damage, electric shock, personal injury, or death.

Connect motor to an overload protective device rated in compliance with local electric codes.

AVERTISSEMENT

Risques d’incendie et d’électrocution pouvant causer des dommages matériels, des blessures et même la mort.

Connecter au moteur du ventilateur électrique un dispositif de protection contre les surcharges conforme aux codes d'’installations électriques en vigueur.

CAUTION

DO NOT OVERHEAT FAN MOTOR

High air temperatures in the fan section can cause the fan motor to burnout. On draw-through air handlers or air handlers with the fan section down the air stream from the heating section, the discharge air temperature of the heating section must not exceed 104°F (40°C).

ATTENTION

Risques de dommages dans le moteur du ventilateur électrique. Si Ia température de l'air a proximité du ventilateurest élevée, le moteurdu ventilateur électrique peut chauffer et brûler. Sur les transmetteurs d'’air à circulation transversale ou les transmetteurs dont le ventilateur est en aval de l'’unité de chauffage, régler la température de l'’air sortant de l'’unité de chauffage à 40°C (104°F).

CAUTION

Equipment damage due to loose fasteners represents improper start-up and equipment abuse. It is not covered by the warranty.

AVERTISSEMENT

Les dommages dus à des attaches installées de façon inappropriée représentent un démarrage inadéquat et un abus d’équipement. Ceci n’est pas couvert par la garantie.

Fa

Sta ba No

A

Fa Fig (H

No

Fig Cu

Ta (H

D n Startup rt and run fan. Observe the rotation. If the fan operates ckward, reverse two legs of the three-phase supply power.

te: Variable pitch fan drives usually are provided for operation in the mid-speed adjustment range. However, the drives usually ship with the adjustment opened up for minimum fan speed. Adjust the drives for the proper airflow. See Fan Drive Adjustments‚ page 28.

fter 48 Hours of Operation Disconnect and lock electrical power source.

Check tightness of all bearing, wheel, and sheave setscrews (or capscrews). Refer to Table 7, page 23.

Recheck belt tension and adjust if necessary. Belts tensioned sufficiently to slip one to two seconds at startup will perform satisfactorily, extending life and reducing vibration. If retensioning is necessary, be certain to retain sheave alignment.

n Wheel Alignment ure 28: Wheel-to-Inlet Funnel Relationship—Fan Wheels oused) te: 1To obtain rated air performance, dimensional relationship must be held.