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1200 Grandview Drive

S. San Francisco, CA 94080


ACCO Job No. 622633
PM - Rob Risse

Mechanical Contractor/Engineer
Building Confidence in Design, Construction & Service
1133 Aladdin Avenue
San Leandro, CA 94577

OPERATION AND MAINTENANCE


MANUALS
INDEX

1.

TRANE Split System ...............................................................................Tab 1

2.

ABB Variable Frequency Drives. ...........................................................Tab 2

3.

McQUAY Skyline Rooftop Unit .............................................................Tab 3

4.

TITUS DESV VAV Boxes .......................................................................Tab 4

5.

GREENHECK Fans ................................................................................Tab 5

6.

GREENHECK Control Damper ............................................................Tab 6

7.

RUSKIN Fire/Smoke Dampers...............................................................Tab 7

8.

B&G Pumps

....................................................................................Tab 8

1133 Aladdin Avenue San Leandro, CA 94577 (T) 510-346-3400 (F) 510-347-1308
Contractors License #120696

For Maintenance or Warranty Service:

Building Confidence in Design, Construction & Service

(800) 598-2226
1133 Aladdin Avenue
San Leandro, CA 94577-4311
Fax (510) 347-1318

TAB 1

TTA-IN-4C
18-AC32D5-4

INSTALLER'S
GUIDE
Model:

TTA030-036C,
& TTA042-072D

Library
Product Section
Product
Model
Literature Type
Sequence
Date
File No.
Supersedes

Service Literature
Unitary
Split System Cooling
TTA
Installer's Guide
4C
January 1999
SV-UN-S/S-TTA-IN-4C 1/99
TTA-IN-4B

Condensing Units

IMPORTANT This Document is customer property and is to remain with this unit. Please return to service information pack upon completion
of work.

These instructions do not cover all variations in systems


nor provide for every possible contingency to be met in
connection with installation. All phases of this installation must comply with NATIONAL, STATE AND LOCAL
CODES. Should further information be desired or should
particular problems arise which are not covered sufficiently for
the purchasers purposes, the matter should be referred to your
installing dealer or local distributor.

TOP DISCHARGE --- UNRESTRICTED


5 FT. ABOVE UNIT

A. GENERAL
The following instructions cover the TTA030-036C, &
TTA042-072D.
NOTICE: These outdoor units may be used with indoor
units equipped with Capillary Tube, Thermostatic Expansion Valve or the Accutron Flow Control Check
Valve (F.C.C.V.) assembly for refrigerant flow control.
Check for transportation damage after unit is uncrated. Report
promptly, to the carrier, any damage found to the unit.
To determine the electrical power requirements of the unit,
refer to the nameplate of the unit. The electrical power available must agree with that listed on the nameplate.
B. LOCATION & PREPARATION OF THE UNIT
1. The unit should be set on a level support pad at least as large
as the unit base pan.
2. The support pad must NOT be in direct contact with any
structure. The unit must be positioned a minimum of 12" from
any wall or surrounding shrubbery to insure adequate airflow.
A 30" clearance must be provided in front of control box (access
panels) & any other side requiring service access to meet
National Electrical Code. The unit must be far enough away
from any structure to prevent excess roof run-off water from
pouring directly on the unit.
3. The top discharge area must be unrestricted for at least five
(5) feet above the unit.
4. When the outdoor unit is mounted on a roof, be sure the roof
will support the units weight. Properly selected vibration
isolators are recommended to prevent transmission to the
building structure.
5. The maximum length of refrigerant lines from outdoor to
indoor unit should NOT exceed sixty (60) feet.

American Standard Inc. 1999

6. If the outdoor unit is mounted above the air handler, maximum lift should not exceed sixty (60) feet (suction line). If air
handler is mounted above the condensing unit, maximum lift
should not exceed sixty (60) feet (liquid line).
NOTE: Refer to Refrigerant Piping Guide, Pub. No. 22-3238-02.
7. Locate and install indoor coil or blower coil in accordance
with instruction included with that unit.

Since the manufacturer has a policy of continuous


product improvement, it reserves the right to change
specifications and design without notice.

INSTALLER'S GUIDE
C. ACCUTRON FLOW CONTROL VALVE
If the indoor unit System Refrigerant Flow control is an
Accutron orifice and check valve assembly, an orifice size
change may be necessary.
The outdoor model determines the required orifice size. Check
the listed orifice size on nameplate of the selected outdoor
model. If the indoor unit is factory shipped with a different
orifice size, the orifice must be changed to obtain system rated
performance.
IMPORTANT: The outdoor unit is shipped with the proper
size orifice and a stick-on orifice size label in an envelope
attached to the outdoor unit. Outdoor unit nameplate will have
correct orifice size specified as BAYFCCV --- A for rated
performance.

BRAZE TYPE INDOOR END


SEALING CAP
ACCUTRONTM
COMPONENTS

ADAPTER
FLOW CONTROL
CHECK VALVE
(F.C.C.V.) ORIFICE

BODY

D. INSTALLING REFRIGERANT LINES


Condensing units have provisions for braze connections.

AS SHIPPED

Pressure taps are provided on the service valves of outdoor unit


for compressor suction and liquid pressures.
The indoor end of recommended refrigerant line sets may be
straight or with a 90 degree bend, depending upon situation
requirements. This should be thoroughly checked out before
ordering refrigerant line sets.
The gas line must always be insulated.
The units are factory charged with the system charge required
when using fifteen (15) feet of connecting line. Unit nameplate
charge is the same. If final refrigerant charge adjustment is
necessary, use the Charge Charts in the outdoor unit Service
Facts.
1. Determine the most practical way to run the lines.
2. Consider types of bends to be made and space limitations.
NOTE: Large diameter tubing will be very difficult to rebend
once it has been shaped.
3. Determine the best starting point for routing the refrigerant
tubing--INSIDE OR OUTSIDE THE STRUCTURE.
4. Provide a pull-thru hole of sufficient size to allow both liquid
and gas lines plus fittings to clear. The location of this hole (if
practical) should be just above the wall plate which is resting on
the foundation.
5. Be sure the tubing is of sufficient length.

FIELD SUPPLIED
LIQUID LINE

E. SERVICE VALVE OPERATION


BRASS LIQUID AND GAS LINE SERVICE VALVE
OPERATION
The Service Valves are factory shipped in the seated position to
hold factory charge. The pressure tap service port (when
depressed) opens only to the field brazing side of the valve when
the valve is in the seated position. The liquid line valve is not
a back seating valve (see WARNING below).

WARNING:

Extreme caution should be


exercised so the internal steel stem retaining ring is not
damaged by backing out the valve stem when opening
the valve. If the valve stem is forced out past the
retaining ring, system pressure could force the valve
stem out of the valve body. If the retaining ring is
missing, do not attempt to open the valve. See Figure 3.
BRASS GAS LINE BALL SERVICE VALVE
The Brass Gas Line Ball Service Valve is shipped in the closed
position to hold the factory refrigerant charge. The pressure tap
service port (when depressed) opens only to the field brazing
side when the valve is in the closed position.

6. Uncoil the tubing --- do not kink or dent.

The Gas Line Service Valve is full open with a 1/4 turn counterclockwise. See Figure 4.

7. Route the tubing making all required bends and properly


secure the tubing before making connections.

BRAZING REFRIGERANT LINES

8. To prevent a noise within the building structure due to


vibration transmission from the refrigerant lines, the following
precautions should be taken:
a. When the refrigerant lines have to be fastened to floor
joists or other framing in a structure, use isolation type hangers.

1. Before brazing, remove plugs from external copper stub


tubes. Clean internal and external surfaces of stub tubes prior
to brazing.
2. Cut and fit tubing minimizing the use of sharp 90 bends.
3. Insulate the entire gas line and its fittings.

b. Isolation hangers should also be used when refrigerant


lines are run in stud spaces or enclosed ceilings.

4. Do NOT allow uninsulated liquid line to come in direct


contact with bare gas line.

c. Where the refrigerant lines run through a wall or sill,


they should be insulated and isolated.

5. Precautions should be taken to avoid heat damage to


the pressure tap valve core during brazing. It is recommended that the pressure tap port valve core be removed
and a wet rag wrapped around the valve body.

d. Isolate the lines from all ductwork.

NOTICE: Use care to make sure that no moisture enters


pressure tap port, while wet rag is being used.

PAGE 2

Pub. No. 18-AC32D5-4

INSTALLER'S GUIDE
3

LIQUID LINE SERVICE VALVE

GAS LINE SERVICE VALVE


CAP
RETAINING RING

UNIT SIDE OF
SERVICE VALVE

UNIT SIDE OF
SERVICE VALVE

LIQUID LINE
CONNECTION

HEX HEADED
VALVE SYSTEM

HEX HEADED
VALVE SYSTEM

LIQUID LINE
CONNECTION

CAP
RETAINING RING

6. Remove braze shield from clear plastic bag. Soak pad in


water and place over suction and liquid lines to protect unit
finish. See figure 5. Discard pad when finished with brazing.
7. Use a Dry Nitrogen Purge and Brazing Alloy without flux
when brazing the field line to the copper factory connection.
Flow dry nitrogen into either valve pressure tap port, thru the
tubing and out the other port while brazing.
8. Braze using accepted good brazing techniques.
LEAK CHECK

CAUTION:

In scroll compressor applications, dome temperatures may be hot. Do not touch top
of compressor, may cause minor to severe burning.
IMPORTANT: Replace pressure tap port valve core
before attaching hoses for evacuation.
After brazing operation of refrigerant lines to both the outdoor
and indoor unit is completed, the field brazed connections must

be checked for leaks. Pressurize through the service valve


ports, the indoor unit and field refrigerant lines with dry
nitrogen to 200 psi. Use soap bubbles or other leak-checking
methods to see that all field joints are leak-free! If not, release
pressure; then repair!
SYSTEM EVACUATION
NOTE: Since the outdoor unit has a refrigerant charge, the gas
and liquid line valves must remain closed.
1. Upon completion of leak check, evacuate the refrigerant
lines and indoor coil before opening the gas and liquid line
valves.
2. Attach appropriate hoses from manifold gauge to gas and
liquid line pressure taps.
NOTE: Unnecessary switching of hoses can be avoided and
complete evacuation of all lines leading to sealed system can be
accomplished with manifold center hose and connecting branch
hose to a cylinder of HCFC-22 and vacuum pump.
3. Attach center hose of manifold gauges to vacuum pump.

GAS LINE SERVICE VALVE


CAP

1/4 TURN ONLY


COUNTERCLOCKWISE
FOR FULL OPEN
POSITION
VALVE STEM

UNIT SIDE
OF VALVE

4. Evacuate until the micron gauge reads no higher than 350


microns.
5. Close off valve to vacuum pump and observe the micron
gauge. If gauge pressure rises above 500 microns in one (1)
minute, then evacuation is incomplete or system has a leak.
6. If vacuum gauge does not rise above 500 microns in one (1)
minute, the evacuation should be complete.

PRESSURE TAP PORT


GAS LINE CONNECTION

NOTE: DO NOT VENT REFRIGERANT INTO THE


ATMOSPHERE.

CAP

BODY

COOLING

CORE

Pub. No. 18-AC32D5-4

7. With a vacuum pump and micron gauge blanked off, open


valve on HCFC-22 cylinder and charge refrigerant lines and
indoor coil with vapor to tank pressure of HCFC-22 supply.

8. Close valve on HCFC-22 supply cylinder. Close valves on


manifold gauge set and remove refrigerant charging hoses from
liquid and gas pressure tap ports.
NOTE: A 3/16" Allen wrench is required to open liquid line
service valve. A 1/4" Open End or Adjustable wrench is required
to open gas line valve. An Adjustable or 3/4" Open End wrench
is required to take off the valve stem cap.

PAGE 3

INSTALLER'S GUIDE
5

3. Install a separate disconnect switch at the outdoor unit.

HEAT SHIELD

4. Ground the outdoor unit per local code requirements.


5. Provide flexible electrical conduit whenever vibration transmission may create a noise problem within the structure.
6. The use of color coded low voltage wire is recommended to
simplify connections between the outdoor unit, the thermostat,
and the indoor unit.
Table 1 --- NEC Class II Control Wiring

24 VOLTS
WIRE SIZE

MAX. WIRE LENGTH

*22 AWG

30 FT.

20 AWG

100 FT.

18 AWG

150 FT

16 AWG

225 FT.

14 AWG

300 FT.

*If 22 AWG is used, make sure it is high quality wire.


9. The liquid line shut-off valve can now be opened. Remove
shut-off valve cap. Fully insert hex wrench into the stem and
backout counterclockwise until valve stem just touches retainer ring (approximately five (5) turns) observing WARNING
statement. See Figure 3.
10. Replace liquid service pressure tap port cap and valve stem
cap. These caps MUST BE REPLACED to prevent leaks.
Replace valve stem and pressure tap cap finger tight, then
tighten an additional 1/6 turn.
11. The gas valve can now be opened. For a ball type gas valve,
open the valve by removing the shut-off valve cap and turning
the valve stem 1/4 turn counterclockwise. See Figure 4. For
brass gas line service valve opening, follow items 9 & 10 above.
See Figure 3.
12. The gas valve is now open for refrigerant flow. Replace
valve stem cap to prevent leaks. See Figures 3 & 4.

7. Table 1 defines maximum total length of low voltage wiring


from outdoor unit, to indoor unit, and to thermostat.
8. Mount the indoor thermostat in accordance with instruction
included with the thermostat. Wire per appropriate hook-up
diagram (included in these instructions).
G. COMPRESSOR SUMP HEAT
After all electrical wiring is complete, SET THE THERMOSTAT SYSTEM SWITCH IN THE OFF POSITION SO
COMPRESSOR WILL NOT RUN, and apply power by closing
the system main disconnect switch. This will activate the
compressor sump heat. Do not change the Thermostat System
Switch until power has been applied long enough to evaporate
any liquid HCFC-22 in the compressor (30 minutes for each
pound of HCFC-22 in the system as shown on the nameplate).
Following this procedure will prevent compressor damage at
the initial startup.

It may be necessary to adjust system refrigerant charge upon


completion of installation. System should be operated and
checked for proper charge.

Record the POWER APPLIED DATE on the designated lines


below:

F. ELECTRICAL CONNECTIONS

Time _____________________A.M./P.M.

CAUTION:

Date ______________

Three phase scroll compressors


will run in reverse if powered up with improper phasing.
If the compressor is running backwards there will be
little or no difference in suction and discharge pressure
and it will make a distinct louder sound. Reversing any
two of the field installed power leads will correct the
compressor rotation. Failure to change the power leads
to correct compressor rotation may result in compressor
damage during operation.

By ______________________________________________________
(Electrician)

WARNING:

Final phases of this installation are the unit Operational and


Checkout Procedures which are found on page 8 of this instruction.

When installing or servicing


this equipment, ALWAYS exercise basic safety precautions to avoid the possibility of electric shock.
1. Power wiring and grounding of equipment must comply with
local codes.

H. ELECTRICAL HEATERS
Electric heaters, if used, are to be installed in the air handling
device according to the instructions accompanying the air
handler and the heaters.
I. OPERATIONAL AND CHECKOUT PROCEDURES

J. OUTDOOR THERMOSTAT
An outdoor thermostat TAYSTAT250A may be field installed.
For data, see wiring diagram attached to unit and instruction
sheet packaged with outdoor thermostat.

2. Power supply must agree with equipment nameplate.

PAGE 4

Pub. No. 18-AC32D5-4

INSTALLER'S GUIDE
TTA030-036C, & TTA042-072D OUTLINE DRAWING
NOTE: ALL DIMENSIONS ARE IN MM (INCHES).

MODELS

FIG.

TTA030C

24-3/8

28-1/4

24-5/8

3/4

5/16

TTA036C

24-3/8

28-1/4

24-5/8

7/8

3/8

TTA042D

32-3/4

28-1/4

24-5/8

7/8

3/8

TTA048D

28-5/8

32-7/8

28-3/4

1-1/8

3/8

TTA060D

40-5/8

32-7/8

28-3/4

1-1/8

3/8

TTA072D

37

38-7/8

34-3/4

1-1/8

3/8

GAS LINE BALL SERVICE VALVE,


BALL 1/4 TURN "D" O.D. FEMALE
BRAZED CONNECTION WITH 1/4"
SAE FLARE PRESSURE TAP FITTING

NOTE: TABLE IN INCHES ONLY


From Dwg. 21D147561 Rev. 9

Pub. No. 18-AC32D5-4

PAGE 5

INSTALLER'S GUIDE
A TYPICAL FIELD WIRING DIAGRAM FOR TTA030-072 WITH AIR HANDLER
NOTES:
1. POWER WIRING AND GROUNDING OF EQUIPMENT MUST
COMPLY WITH LOCAL CODES.
2. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT
NAMEPLATE.
3. LOW VOLTAGE WIRING TO BE NO. 18 A.W.G. MINIMUM
CONDUCTOR.
4. USE COPPER CONDUCTORS ONLY.
5. POLARIZED PLUG SECTION PM-A IS ATTACHED TO HEATER
CONTROL BOX.
6. IF ODT IS NOT USED, THEN CONNECT APPROPRIATE
JUMPER FROM W1 TO W2 ON LVTB.

From Dwg. 21B131075 Rev. 2

A TYPICAL FIELD WIRING DIAGRAM FOR TTA030-072 WITH


FURNACE FOR SINGLE STAGE HEATING, SINGLE STAGE COOLING
NOTES:
1. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE(S).
2. LOW VOLTAGE (24V.) WIRING TO BE NO. 18 A.W.G. MIN.
3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.
4. SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.
5. THE "Y" TERMINAL FROM THE THERMOSTAT MUST BE WIRED TO
THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER
BLOWER OPERATION DURING COOLING.

From Dwg. 21B340432 Rev. 0

PAGE 6

Pub. No. 18-AC32D5-4

INSTALLER'S GUIDE
CHECKOUT PROCEDURE
After installation has been completed, it is recommended that the entire system be checked against the
following list:
1. Refrigerant Line, Leak checked ..........................................................................................................
2. Suction Lines and Fittings properly insulated ......................................................................................
3. Have all Refrigerant Lines been secured and isolated properly?........................................................
4. Have passages through masonry been sealed? If mortar is used, prevent mortar from
coming into direct contact with copper tubing .....................................................................................
5. Indoor coil drain line drains freely. Pour water into drain pan .............................................................
6. Supply registers and return grilles open and unobstructed .................................................................
7. Return air filter installed ......................................................................................................................
8. Thermostat thermometer is accurate. Check against a reliable thermometer. Adjust
per instructions with thermostat ..........................................................................................................
9. Is correct speed tap being used? (Indoor blower motor) ....................................................................

[ ]
[ ]
[ ]
[
[
[
[

]
]
]
]

[ ]
[ ]

SYSTEM OPERATIONAL CHECK


OPERATING PRESSURES: After the unit has operated in the cooling mode for a short period of time, install
pressure gauges on the gauge ports of the discharge and suction line valves. Check the suction and discharge
pressures and compare them to the normal operating pressures provided in the units Service Facts.
NOTE: Use the pressures from Service Facts to determine the unit refrigerant charge.
To charge the system accurately, use superheat charging, or pressures
depending on flow control.
1. Except as required for safety while servicing: DO NOT OPEN SYSTEM DISCONNECT SWITCH.

SUPPLEMENTARY HEATERS CHECKOUT PROCEDURES, IF USED


DOES HEATER REQUIRE A SEPARATE CIRCUIT?
1. Be sure the fused disconnect switch is OFF, and safety label (if any) is attached ................................ [ ]
2. Check on field wiring for sound connections and grounding according to codes .................................... [ ]
3. Check fuses for proper size per nameplate specifications ..................................................................... [ ]
4. Check control box panel in place and secured .................................................................................. [ ]
NOTE: OPERATION OF HEATERS MUST BE CHECKED DURING THE OPERATION CHECK OF THE TOTAL
SYSTEM.

Pub. No. 18-AC32D5-4

PAGE 7

INSTALLER'S GUIDE
CHECKOUT PROCEDURE WITH MAIN POWER DISCONNECTS CLOSED (ON)
INDOOR THERMOSTAT
SWITCH SETTING
Step
No.

TO CHECK

Off

1
Cool

1
Heat

COMPONENT OPERATION

On

Indoor
Blower
Runs

Fan Switch
Auto

Outdoor
Fan
Runs

Compressor
Runs

Comp.
Sump
Heater

Sump Heat

Indoor Fan Operation

Cooling Operation

Checking Performance
& Charge

Furnace
Heat
Comes On

X
X

USE CHARTS ATTACHED TO O.D. UNIT

Heating 2

Inform owner on how to operate system and what to expect of it. At the same time deliver Owners Use and Care Booklet.

1 Also set thermostat dial to call for cooling or heating as necessary.


2 Check only necessary if heating unit is used for indoor section and wiring has been disturbed during installation of cooling
equipment.

Technical Literature - Printed in U.S.A.

The Trane Company


Unitary Products Group

6200 Troup Highway


Tyler, TX 75707

PAGE 8

Pub. No. 18-AC32D5-4


P.I.

Service Facts

GAM5A0B30M21-SF-1C

Air Handler-Convertible
Model: GAM5A0B30M21SA

IMPORTANT --- This document contains a wiring diagram and service information. This is customer property and is to remain with
this unit. Please return to service information pack upon completion
of work.

*For use with BAYEA series heaters ONLY

WARNING: HAZARDOUS VOLTAGE - DISCONNECT POWER BEFORE SERVICING


PRODUCT SPECIFICATIONS
MODEL
RATED VOLTS/PH/HZ.
RATINGS 1
INDOOR COIL Type
Rows F.P.I.
Face Area (sq. ft.)
Tube Size (in.)
Refrigerant Control
Drain Conn. Size (in.) 2
DUCT CONNECTIONS
INDOOR FAN Type
Diameter-Width (In.)
No. Used
Drive - No. Speeds
CFM vs. in. w.g.
No. Motors H.P.
Motor Speed RPM
Volts/Ph/Hz
F.L. Amps
FILTER
Filter Furnished?
Type Recommended
No.-Size-Thickness
REFRIGERANT
Ref. Line Connections
Coupling or Conn. Size in. Gas
Coupling or Conn. Size in. Liq.
DIMENSIONS
Crated (In.)
Uncrated
WEIGHT
Shipping (Lbs.)/Net (Lbs.)

GAM5A0B30M21SAA
208-230/1/60
See O.D. Specifications
Plate Fin
3 - 14
4.13
3/8
EEV
3/4 NPT
See Outline Drawing
Centrifugal
11 X 10
1
Direct - 5
See Fan Performance Table
1 - 1/3
1050
208-230/1/60
2.8
No
Throwaway
1 - 20 X 20 - 1 in.
R-410A
Brazed
3/4
3/8
HxWxD
53 x 24-1/4 x 25-3/4
51-1/2 x 21-1/4 x 21-3/4
140/132

1 These Air Handlers are A.R.I. certified with various Split System Air Conditioners
and Heat Pumps (ARI STANDARD 210/240). Refer to the Split System Outdoor
Unit Product Data Guides for performance data.
2 3/4" Male Plastic Pipe (Ref.: ASTM 1785-76)

NOTICE: Since the manufacturer has a policy of continuous product and product data
improvement, it reserves the right to change design and specifications without
notice.

2011 Trane

! WARNING
SAFETY hazard! This information is intended for use

by individuals possessing adequate backgrounds of electrical and


mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage.
The manufacture or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection
with its use.

! WARNING
LIVE ELECTRICAL COMPONENTS! During instal-

lation, testing, servicing, and troubleshooting of this product, it may


be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical
components could result in death or serious injury.

! WARNING
PRESSURIZED REFRIGERANT! SYSTEM CONTAINS
OIL AND REFRIGERANT UNDER HIGH PRESSURE. RECOVER
REFRIGERANT TO RELIEVE PRESSURE BEFORE OPENING THE
SYSTEM.

DO NOT USE NON-APPROVED REFRIGERANTS OR REFRIGERANT


SUBSTITUTES OR REFRIGERANT ADDITIVES.

Note: This unit is certified to UL 1995.


The interior cabinet wall meets the following:
- UL94-5VA Flame Class Listed
- UL723 Steiner Tunnel Listed for 25/50 Flame/
Smoke
- UL746C Listed for Exposure to Ultraviolet Light,
Water Exposure and Immersion

AIRFLOW PERFORMANCE
GAM5A0B30M21SAA
EXTERNAL STATIC
(in w.g)

AIRFLOW (CFM)
Speed Taps - 230 VOLTS

Speed Taps - 208 VOLTS

1282

1150

979

856

678

1279

1146

976

853

675

0.1

1238

1094

931

797

482

1232

1088

925

791

476

0.2

1186

1047

863

725

285

1177

1039

854

716

276

0.3

1141

986

803

647

88

1130

975

791

636

77

0.4

1091

935

721

555

1076

921

707

540

0.5

1033

866

649

461

1016

849

632

444

0.6

977

799

554

388

958

779

534

369

0.7

914

732

490

318

892

710

468

296

0.8

846

646

429

821

621

404

0.9

771

587

376

743

560

348

NOTES:
1. Values are with wet coil and without filters.
2. Contact your particular filter manufacturer for pressure drop data.
3. Electric heater pressure drop is negligible and is included within the airflow data.
4. Tap 1 is an continuous fan speed tap.

GAM5A0B30M21SAA MINIMUM HEATER AIRFLOW CFM


Heater

Minimum Air Speed Tap


With HP

Without HP

BAYEAAC05BK1AA
BAYEAAC05LG1AA

Tap 3

Tap 2

BAYEAAC08BK1AA
BAYEAAC08LG1AA

Tap 4

Tap 3

BAYEAAC10BK1AA
BAYEAAC10LG1AA

Tap 4

Tap 3

BAYEABC15BK1AA

Tap 5

Tap 4

BAYEABC20BK1AA

BAYEACC25BK1AA

SEE AIR HANDLER NAMEPLATE OR PRODUCT DATA FOR EXCEPTIONS

Note: Heating and cooling speeds are the same, factory


set at Speed Tap #4.
Note: A G only signal from the comfort control will run
the blower at a lower speed, factory set at Speed Tap #1.
See the Sequence of Operation for additional information.

GAM5A0A30M21-SF-1C

WIRING DATA
GAM5A0B30M21SAA
240 VOLT
Heater
Model
No.

No.
of
Circuits

kW
No Heater

BAYEAAC05++

BAYEAAC08++

BAYEAAC10++

circuit 1

208 VOLT

BTUH

Heater
Amps
per
Circuit

Minimum
Circuit
Ampacity

Maximum
Overload
Protection

kW

2.8*

15

4.80

16400

20

29

30

7.68

26200

32

44

45

9.60

32800

40

54

9.60

49200

40

4.80

49200

20

Capacity

BTUH

Heater
Amps
per
Circuit

Minimum
Circuit
Ampacity

Maximum
Overload
Protection

2.8*

15

3.60

12300

17.3

25

25

5.76

19700

27.7

38

40

60

7.20

24600

34.6

47

50

54

60

7.20

36900

34.6

47

50

25

25

3.60

36900

17.3

22

25

Capacity

BAYEABC15++
circuit 2
Note: * Motor Amps

DISTANCE FROM BELLY BAND TO SHAFT FACE OF MOTOR FOR MINIMUM VIBRATION
BLOWER HOUSING
BELLY BAND
A
MOTOR
WHEEL

A is determined per chart


Wheel is centered in
Blower Housing

MODEL

DIM "A"

GAM5A0A18M11SA

1-1/8

GAM5A0A24M21SA

1-1/8

GAM5A0B30M21SA

1-1/8

GAM5A0B36M31SA

1-1/2

GAM5A0C42M31SA

1-1/2

GAM5A0C48M41SA

2-1/4

GAM5A0C60M51SA

2-1/4

GAM5A0A30M21-SF-1C

GAM5A0A30M21-SF-1C

WIRING DIAGRAM FOR GAM5A0B30M21SAA

SEQUENCE OF OPERATION FOR GAM5A0B30M21SAA


3. The combination of 24VAC on the Y terminal and zero
volts on the O terminal signals the EVC that the unit is in
heat-pump heating mode.

GAM5 Sequence of Operation:


Abbreviations
TDR = Time Delay Relay

4. Normally closed contacts on the EVC will pass 24VAC


to the YO terminal providing power to the outdoor unit
control circuit

EVC = Expansion Valve Control


EEV = Electronic Expansion Valve

5. The blower motor will now run on high speed

YI = Y signal into the EVC from the comfort control

Cooling OD

YO = Y signal out of the EVC from the comfort control


OEM = Original Equipment Manufacturer

1. R-Y contacts close on the comfort control sending 24VAC


to Y terminal on TDR and the YI (Y In) terminal on the
EVC

See unit, electric heat, and field wiring diagrams for additional
information.

2. R-G contacts also close on the comfort control sending


24VAC to the G terminal on the TDR. (The combination
of 24VAC on terminals Y and G on the TDR will close
the high speed contacts of the TDR)

Continuous Fan

3. R-O jumper on the TDR sends 24VAC to the O terminal


on the EVC. This signals the EVC that the unit is in cooling mode. The EVC will control the EEV to maintain the
correct superheat.

IMPORTANT: If the indoor air exceeds 60% relative


humidity or simply feels uncomfortably humid, it is recommended that the indoor fan only be used in the AUTO
mode.

4. Normally closed contacts on the EVC will pass 24VAC


to the YO terminal providing power to the outdoor unit
control circuit

1. R-G contacts close on comfort control sending 24VAC to the


G terminal on the fan TDR

5. The blower motor will now run on high speed

2. Low speed contacts close in the TDR and send 24VAC on


terminal labeled LOW.

Electric Heating

3. Blower motor will now run on low speed. Speed is field


selectable.

1. R-W contacts close on the comfort control sending 24VAC


to the W terminal on the TDR. 24VAC is also sent to
EHC to energize the heat relay.

Heat Pump OD (cooling)

2. R-G contacts close on the comfort control sending 24VAC


to the G terminal on the TDR. (The combination of
24VAC on terminals W and G on the TDR will close the
high speed contacts of the TDR)

1. R-Y contacts close on the comfort control sending 24VAC to


Y terminal on TDR and the YI (Y In) terminal on the EVC.
2. R-G contacts also close on the comfort control sending
24VAC to the G terminal on the TDR. (The combination
of 24VAC on terminals Y and G on the TDR will close the
high speed contacts of the TDR)

3. WJ contacts on the TDR close providing an interlock


circuit to allow the electric heat relays to operate.
The comfort control must be setup to control R-G contacts
with a call for electric heat. This closes the interlock
circuit and allows the heat relay circuit to be energized.

3. R-O contacts on the comfort control close sending 24VAC to


the O terminal on the EVC. This signals the EVC that the
unit is in cooling mode. The EVC will control the EEV to
maintain the correct superheat.

Optional Condensate Switch

4. Normally closed contacts on the EVC will pass 24VAC to


the YO terminal providing power to the outdoor unit control
circuit

1. An optional OEM condensate switch can be installed


within the unit. This switch is only available through the
National Distribution Center or Global Parts.

5. The blower motor will now run on high speed. Speed is field
selectable.

2. Switch contacts are normally open and close when water


level rises. The closed switch will interrupt current flow to
the YO terminal and de-energize the OD unit.

Heat Pump OD (heating)


1. R-Y contacts close on the comfort control sending 24VAC to
Y terminal on TDR and the YI (Y In) terminal on the EVC

3. Switch is only operational during cooling mode. Condensate overflow is not operational during heating or defrost
modes.

2. R-G contacts also close on the comfort control sending


24VAC to the G terminal on the TDR. (The combination
of 24VAC on terminals Y and G on the TDR will close the
high speed contacts of the TDR) The blower motor will now
run on high speed.

Standard aftermarket condensate switches cannot be used


within the unit but can be installed exterior of the unit.
Switch should be wired in series with YO wiring to the
OD unit.

GAM5A0A30M21-SF-1C

Freeze Protection
1. The EVC control has the ability to sense when the coil is
beginning to ice. When this event occurs, the contacts to
the YO circuit will open and de-energize the OD unit.
2. The indoor blower motor will continue to run to aid in defrosting the coil. After the coil has sufficiently defrosted,
the YO contacts will close and cooling operation will begin
again.

Fan Off Delay


1. The TDR has a dip switch that can enable a 90 second
fan off delay anytime a fan call is made from the comfort
control. The factory default is ON. To disable the delay, turn
power off to the unit, turn the dip switch to the off position
and turn power back on to the unit.

DIP SWITCH SETTING - Refrigeration Switch

Wire Ties

Note: Ensure that the system refrigerant is set


to match your application, either R-410A or R-22.
using the Refrigerant Switch located on the Expansion Valve Control board (EVC) in the Control
Pocket.
Factory default is R-410A.

Note: A power cycle is needed for the EVC to


recognize the change.
SW1
410

GAM5A0A30M21-SF-1C

22

SW1
410
1
2
3

22

CONFIGURATION DIP SWITCH SETTINGS


SW2 Switch Settings (Configuration)
DS1

DS2

DS3

OFF

ON

OFF

ON

ON

OFF

OFF

OFF

ON

ON

OFF

ON

Model Number
GAM5A0A18M11SA
GAM5A0A24M21SA
GAM5A0B30M21SA
GAM5A0B36M31SA
GAM5A0C42M31SA
GAM5A0C48M41SA
GAM5A0C60M51SA
DS1
DS2
DS3

SW1
410

22

1
2
3

EVC STATUS
EVC STATUS LED (Non Heat Pump Systems)
Flash
1
3

Cool mode / No active call


Active call for cooling

EVC STATUS LED (Heat Pump Systems)


Flash
1
3
4
6

Cool mode / No active call


Active call for cooling or defrost
Heat mode selected or System switch off
Active call for heating

NOTE: Status LED is for determining EVC control state only. Auxiliary heat status is not reported.

EVC FAULT CODES


LED Color

RED

EVC Fault
LED
OFF
1
2
3
4
5
6
7
10
11
13

NOTES:

Description
Standby
Stepper Motor coil has an open circuit or intermittent short (Replace coil)
Control has detected an internal failure (Replace EEV control, EVC)
Saturated Gas Sensor input out of range (Verify resistance, 5VDC output from control) (1)
Evaporator Gas Sensor input out of range (Verify resistance, 5VDC output from control) (1)
Stepper Motor Coil is shorted (Replace coil) (2)
Valve is not responding to a change in position. (Possible stuck valve)
High superheat (Low charge or restriction)
Low superheat (Check airflow, possible stuck valve) (3)
Condensate drain switch activated for 100 seconds (Check condensate switch and drain) (2)
Indoor frost protection activated (Check refrigerant charge and airflow) (2)
1) EEV will try to go to a safe position, cooling attempt allowed
2) K1 relay opens on EVC, Yo disabled
3) Cooling attempt allowed, 5 consecutive Y calls with same condition disables Yo
4) Faults 6, 7, & 10 may require jumper from "Test - Close" for 10 seconds to clear fault LED
7

GAM5A0A30M21-SF-1C

THERMAL RESISTANCE AND VOLTAGE TABLE

J2

Configuration
See Table

J4

C4

K1

U2

22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6

11024
10492
9990
9515
9065
8639
8236
7855
7493
7150
6825
6516
6224
5946
5682
5432
5194
4968
4753
4548
4354
4169
3992
3825
3665
3513
3368
3230
3098
2972
2853
2738
2629
2525
2425
2330
2239
2153
2070
1990

1.54
1.49
1.44
1.39
1.34
1.29
1.25
1.20
1.16
1.12
1.08
1.04
1.01
0.97
0.93
0.90
0.87
0.84
0.81
0.78
0.75
0.72
0.70
0.67
0.65
0.62
0.60
0.58
0.56
0.54
0.52
0.50
0.48
0.46
0.45
0.43
0.42
0.40
0.39
0.37

C9

C3

L2

C8

MH3

1-

1
2
3
R74R70
D21

R54

R8
R45
D16D17
R39
R17
C26
R57
R60 R25
C25 R29
C15
R62
C19
R63
C24 C20 L4 C14
R75 U4
R64
R55
R81
R53
R52
R76
R51

D22

C28
C27

R71
D23

X1

D24
J5

D4

C10

C11

R41

R16R35 Q6

Q2

D7
U1

C18
C34

Q1

R42
R10

R43

D2
R6R34Q5

D11

R11
R56

R47

ON

R4

R32
R37

OFF

22

R31
C22

ON

Q9

R40
R5
C37 R44
R3
D1
R15
R14
D5

Q3

C1

J1

P/N LABEL

TRANE U.S. INC.

J1

To EEV Stator

J6

L1
+12V

R83
Q7
R20
R59
C7
R19 C16
D8
C2R36
D20
Q8
Q4
R73
C13R24 R13
R27
C30
R26
R72
L3
R38
D12 C33
R69
R77
C36
C5 C6
D6
R78
R85
R28
R12
R48
C32
Q10
+VDD
R2 R7
C23
C29
R22
GND
R49
D10
C38
MH2

OPEN
TEST
CLOSE

GAM5A0A30M21-SF-1C

72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150

R86 R30

D9

R21

D3
R9

R46

D15

R1

MH1

Volts DC at plug J3
EVAP SAT - Brown to Brown
EVAP GAS - Black to Black

J6

To Internal
Condensate
Switch
(Optional)
Evap Saturation
Evap Gas

D13

SW2

THERMISTOR
RESISTANCE
(OHMS)

D29

SW1 OFF
410

J4

TEMP
C

D19

J7

OPEN
TEST
CLOSE

D26

R410A / R22

YO

D28
R58
R33
MOV1
R61 C21
D30

SW2
1
2
3

C31
R79
D25

SW1

D18

PG
PGC
VS D
S
VD
D
C
LR

Liteport

D14

Y1

R23
C35

J7

STATUS FAULT

FAULT
LED

J2
MH4
R18
D27

R84

STATUS
LED

TEMP
F

EXPANSION VALVE CONTROL BOARD (EVC)

C12

-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0.0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
21.1

Volts DC at plug J3
EVAP SAT - Brown to Brown
EVAP GAS - Black to Black
3.20
3.17
3.14
3.10
3.07
3.04
3.00
2.97
2.93
2.90
2.86
2.83
2.80
2.76
2.73
2.69
2.66
2.62
2.59
2.56
2.52
2.49
2.45
2.42
2.39
2.35
2.32
2.29
2.25
2.22
2.19
2.16
2.12
2.09
2.06
2.03
2.00
1.97
1.94
1.91
1.88
1.85
1.82
1.79
1.76
1.73
1.70
1.67
1.65
1.62
1.59

C17
R66

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

THERMISTOR
RESISTANCE
(OHMS)
45076
43764
42494
41266
40077
38927
37813
36736
35692
34681
33703
32755
31838
30949
30087
29253
28445
27661
26902
26166
25452
24761
24090
23440
22810
22198
21605
21030
20472
19931
19405
18896
18401
17921
17455
17002
16563
16137
15723
15320
14930
14550
14182
13824
13476
13138
12810
12491
12181
11879
11586

R82

TEMP
C

R80

TEMP F

J3

J3

See Table

Vapor Line
Sensor
(EVAP GAS)

Saturation
Sensor
(EVAP SAT)

Electronic Expansion Valve Test


Note: Close Valve and Open Valve Tests are active in any mode of operation
Test Pins: OPEN, CLOSE, TEST (See J4 on EVC Board)

Close Valve Test - Touch CLOSE pin to TEST pin.


EEV drives closed (5 seconds max) and stays closed for 1.5 minutes (90 seconds).

1) Status LED will be flashing.


2) Gauges should indicate suction pressure dropping.
Valve is working.
LPCO may trip.

Note: The Close Valve Test will exit after 1.5 minutes (90 seconds) and will not reinitiate (requires a break and make to
initialize). To clear faults stored in memory, apply a jumper between Close and Test pins for 10 seconds.

Open Valve Test - Touch OPEN pin to TEST pin.


EEV drives open (5 sec max) and stays open for 30 seconds.

1) Status LED will be flashing.


2) Temperature probe should indicate superheat falling.
Valve is working.

Note: If jumper is left on pins, the OPEN VALVE TEST will be cleared after 30 seconds and will not reinitiate (requires a
break and make to reinitialize).

Exit Test Mode -


The Open Valve Test or Closed Valve Test can be cancelled by jumping to the opposite mode Test pin.
The system will return to normal super heat control.
9

GAM5A0A30M21-SF-1C

SUBCOOLING ADJUSTMENT

The following combinations should be charged to 8


degrees sub-cooling to maintain rated HSPF.
Indoor Unit Model No.

Outdoor Unit Model No.

GAM5A0B30M21SAA

4A6B4030E1
4A6H5030E1
4TWB4030E1
4TWR5030E1

All other non-rated matches must be charged


per the nameplate charging instructions.

GAM5A0A30M21-SF-1C

10

Sensor Check

Verify connections for sensors are


plugged in and connected properly

Start Here

Turn system switch on comfort control


to OFF and fan to ON position

Wait 10 minutes

Does voltage(s) measured correspond


to return air temperature?

Verify resistance per


Thermal Resistance Table
and Voltage table.
Sensors are good.

Yes, EVC is good

Measure return air temperature

No, remove J3 connector


and measure VDC

Measure VDC at J3 connector on EVC.


(See EVC table for J3 location)

Is VDC between 4.5 5?

No, replace EVC

11

GAM5A0A30M21-SF-1C

HIGH SUPERHEAT

Superheat above 30F at OD unit

Start Here

Verify that OD
condenser coils
are clean

Verify line set is


properly sized for
application

NO

Is subcooling at the
outdoor unit
between 8-12F?

Perform
temperature
sensor check

YES

Add refrigerant
until subcooling
reaches ~10F

Is liquid line temperature


at the indoor unit within
8F of outdoor liquid line
temperature?

Recheck
superheat

NO

The system is running at


maximum capacity and this
may be causing the high
superheat. Wait until the
indoor temperature is less
than 80F and check the
superheat again.

YES
EEV and coil are working.
Replace EVC
Check operation

Perform OPEN
VALVE test at
EVC. See page 9

YES

Does suction
pressure go
down?

Verify line set size


and charge is
correct

YES
Perform CLOSE
VALVE test at
EVC. See page 9

YES

Does
superheat drop
below 30F?

NO

Is indoor
temperature
>85F?

NO
Ohm coil per FIG 1?

Replace coil

NO

Is ohm reading
correct?

YES
Replace EEV.
Check operation

Figure 1
4 - Phase Coil Control
4 - BLUE

3 - ORANGE

5 - BROWN (COMMON)

2 - YELLOW

6 - RED (COMMON)

1 - WHITE

Brown (common) to Blue or Yellow should measure 46 ohms


Red (common) to Orange or White should measure 46 ohms

GAM5A0A30M21-SF-1C

12

LOW SUPERHEAT

Superheat below 3F at OD unit

Start Here

Verify field wiring


is correct. See
CTM motor trouble
shooting

Is indoor blower
running?

NO

YES

Is filter, coil,
and blower
wheel clean?

NO

Clean or replace
as needed

YES
Perform sensor
check

Perform CLOSE
VALVE test at
EVC. See page 9

Perform OPEN
VALVE test at
EVC. See page 9

Does suction
pressure rise?

Does suction
pressure drop?

NO

YES

YES

Replace EVC

Replace EVC

NO
Ohm coil per FIG1

Replace coil

NO

Is ohm reading
correct?

YES

Replace EEV.
Check operation

Figure 1
4 - Phase Coil Control
4 - BLUE

3 - ORANGE

5 - BROWN (COMMON)

2 - YELLOW

6 - RED (COMMON)

1 - WHITE

Brown (common) to Blue or Yellow should measure 46 ohms


Red (common) to Orange or White should measure 46 ohms

13

GAM5A0A30M21-SF-1C

NOTE: The fan control has a 90


second OFF delay that is
factory set on. To turn this
feature off, turn dip switch to 0
and cycle power to the unit.

Constant Torque Motor


Troubleshooting
Turn comfort to
FAN ON mode

FIGURE 1

Motor does not run


Turn off power.
Check set screw
position and motor
bearings. Correct
or replace as
needed.
Check operation

High voltage should


always be present.
Correct high voltage
wiring.

NO

Does blower
wheel turn
freely?
YES

NO

Is ~230 VAC measured


between terminals L &
N on the motor?
See Figure 1
FIGURE 2

Correct wiring.
Check operation

YES

NO

Is 24VAC measured
from terminal 8(G) to
terminal 9(BL) on the
fan control?

YES

Replace fan control.


Check operation

GAM5A0A30M21-SF-1C

NO

Is ~24 VAC measured


between the wire connected
to C on the motor and the
wire connected to terminal 1
thru 5 on the motor?
See Figure 2

YES
Replace motor.
Check operation

14

This terminal block is located on


the motor. Look for labels below
on the motor side of the
connection.

15

GAM5A0A30M21-SF-1C



Trane
6200 Troup Highway
Tyler, TX 75707
www.trane.com
For more information contact
your local dealer (distributor)

01/11

The manufacturer has a policy of continuous product and product data improvement, and it reserves the right
to change design and specifications without notice.

TAB 2

ACH550

Installation, Operation and Maintenance Manual (I, O & M)


ACH550-UH HVAC Drives (1550 HP)
ACH550-BCR/BDR/VCR/VDR E-Clipse Bypass Drives (1400 HP)
ACH550-PCR/PDR Packaged Drives with Disconnect (1550 HP)

ACH550 Installation, Operation and Maintenance Manual

Safety
Use of warnings and notes
There are two types of safety instructions throughout this manual:
Notes draw attention to a particular condition or fact, or give information on a
subject.
Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment. They also tell you how to avoid the danger. The
warning symbols are used as follows:
Electricity warning warns of hazards
from electricity which can cause
physical injury and/or damage to the
equipment.
WARNING! The ACH550 adjustable speed
AC drive should ONLY be installed by a
qualified electrician.
WARNING! Even when the motor is
stopped, dangerous voltage is present at the
power circuit terminals U1, V1, W1 (L1, L2,
L3) and U2, V2, W2 (T1, T2 T3) and,
depending on the frame size, UDC+ and
UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present
when input power is connected. After
disconnecting the supply, wait at least 5
minutes (to let the intermediate circuit
capacitors discharge) before removing the
cover.
WARNING! Even when power is switched
off from the input terminals of the ACH550,
there may be dangerous voltage (from
external sources) on the terminals of the
relay outputs.
WARNING! When the control terminals of
two or more drives are connected in parallel,
the auxiliary voltage for these control
connections must be taken from a single
source which can either be one of the drives
or an external supply.
WARNING! Disconnect the internal EMC
filter when installing the drive on an IT
system (an ungrounded power system or a

Safety

high-resistance-grounded [over 30 ohm]


power system).
WARNING! Do not attempt to install or
remove EM1, EM3, F1 or F2 screws while
power is applied to the drives input
terminals.
General warning warns about
conditions, other than those caused
by electricity, which can result in
physical injury and/or damage to the
equipment.
WARNING! Do not control the motor with
the disconnecting device (disconnecting
means); instead, use the control panel keys
or commands via the I/O board of the drive.
The maximum allowed number of charging
cycles of the DC capacitors (i.e. power-ups
by applying power) is five in ten minutes.
WARNING! Never attempt to repair a
malfunctioning ACH550; contact the factory
or your local Authorized Service Center for
repair or replacement.
WARNING! The ACH550 will start up
automatically after an input voltage
interruption if the external run command is
on.
WARNING! The heat sink may reach a high
temperature.
Note: For more technical information, contact
the factory or your local ABB representative.

ACH550 Installation, Operation and Maintenance Manual

Contents
This manual is the Operation and Maintenance Manual for the ACH550 Drives.
Complete technical details and programming information are available in the
ACH550 Users Manual, publication number 3AUA0000081823.
1. To determine the type of your drive, refer to its construction code on either:
Serial number label attached on upper part of
the chokeplate between the mounting holes.

SW:
V.2.06B
2030700001

Type code label attached on the heat sink on


the side of the enclosure.
Input
Voltage (U1)
Current (I1n)

3 PH 4863 Hz
200240 Vac
59.4 A

1 PH 463 Hz
200240 Vac
59.4 A

Output
Voltage (U2)
Current (I2n)

3 PH 0500 Hz
0U1 Vac
59.4 A

3 PH 0500 Hz
0U1 Vac
28 A

Power (Pn)

20 HP

10 HP

ACH550-UH-059A-2

S/N

2030700001

ABB Inc.
Made in USA of foreign parts

kAIC

Mfg. Date: 01-December-2005

S/N

Org. Firmware: V.2.06B

2030700001

ACH550-UH-059A-2

Construction
code

2. According to the construction code, proceed to your drives installation, operation,


diagnostics and maintenance information:
UH Below.
VCR, VDR, BCR, BDR (E-Clipse Bypass) page 39.
PCR, PDR (Packaged Drives with Disconnect) page 77.

ACH550-UH

Installation
Study these installation instructions carefully before proceeding. Failure to observe
the warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

1. Prepare for installation


Lifting R1R6
Lift the drive only by the metal chassis.
Lifting R7R8
WARNING! Handle and ship floor mounted enclosures only in the upright position.
These units are not designed to be laid on their backs.
1. Use a pallet truck to move the transport package/enclosure to the installation site.
2. Remove the cabinet side panels for access to the cabinet/pallet mounting bolts.
(6 torx screws hold each cabinet side panel in place. Leave the side panels off until
later.)
3. Remove the 4 bolts that secure the cabinet to the shipping pallet.
WARNING! Use the lifting lugs/bars at the top of the unit to lift R7/R8 drives.
4. Use a hoist to lift the drive. (Do not place drive in final position until mounting site is
prepared.)
Unpack the drive
1. Unpack the drive.
2. Check for any damage and notify the shipper immediately if damaged components
are found.
3. Check the contents against the order and the shipping label to verify that all parts
have been received.
Tools required
To install the ACH550 you need the following:
Screwdrivers (as appropriate for the mounting hardware used)
Wire stripper
Tape measure
Drill
Frame sizes R5R8 with UL type 12 enclosure: Punch for conduit mounting
holes
Frame sizes R7/R8: pallet truck and hoist
For installations involving frame size R6R8: The appropriate crimping tool for
power cable lugs.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

Mounting hardware: screws or nuts and bolts, four each. The type of hardware
depends on the mounting surface and the frame size:
Frame Size

Mounting Hardware

R1R4

M5

#10

R5

M6

1/4 in

R6

M8

5/16 in

R7R8

M10

7/16

Note

Secures free standing cabinets if required.

For installations involving frame size R7R8: Hoist.


WARNING! Before installing the ACH550, ensure the input power supply to the drive
is off.

WARNING! Metal shavings or debris in the enclosure can damage electrical


equipment and create a hazardous condition. Where parts, such as conduit plates
require cutting or drilling, first remove the part. If that is not practical, cover nearby
electrical components to protect them from all shavings or debris.
Flange Mounting Instructions
Frame size

IP21 / UL type 1
Kit

IP54 / UL type 12

Code (English)

Kit

Code (English)

R1

FMK-A-R1

100000982

FMK-B-R1

100000990

R2

FMK-A-R2

100000984

FMK-B-R2

100000992

R3

FMK-A-R3

100000986

FMK-B-R3

100000994

R4

FMK-A-R4

100000988

FMK-B-R4

100000996

R5

AC8-FLNGMT-R5

ACS800-PNTG01U-EN

R6

AC8-FLNGMT-R6

2. Prepare the mounting location


1. Mark the position of the mounting holes.
Note: Frame sizes R3 and R4 have four holes along the top. Use only two. If
possible, use the two outside holes (to allow room to remove the fan for
maintenance).

Note: ACH400 drives can be replaced using the original mounting holes. For R1 and
R2 frame sizes, the mounting holes are identical. For R3 and R4 frame sizes, the
inside mounting holes on the top of ACH550 drives match ACH400 mounts.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

Note: Frame sizes R7 and R8 have mounting holes inside the enclosure base.
Where it is not possible to use either mounting hole at the back of the base, use an
L-bracket at the top of the enclosure to secure the cabinet to a wall or to the back of
another enclosure. Bolt the L-bracket to the enclosure using the lifting lug bolt hole
on the top of the enclosure.
2. Drill holes of appropriate size in the mounting location.
3. Remove front cover
R1R6, UL type 1
1. Remove the control panel, if attached.
2. Loosen the captive screw at the top.
3. Pull near the top to remove the cover.
R1R6, UL type 12
1. If hood is present: Remove screws (2) holding the hood in place.
2. If hood is present: Slide hood up and off of the cover.
3. Loosen the captive screws around the edge of the cover.
4. Remove the cover.
R7R8, Cabinet Door
1. To open the cabinet door, loosen the quarter-turn screws that hold the cabinet door
closed.
R7R8, Side Panels
The side panels were removed to take the cabinet off the pallet. Installation access is
easier if these panels are kept off throughout the installation.
4. Mount the drive

R1R6, UL type 1
1. Position the ACH550 onto the mounting screws
or bolts and securely tighten in all four corners.
Note: Use mounting hardware that permits fan
replacement without removal.

Note: Lift the ACH550 by its metal chassis.


IP2002

2. Non-English speaking locations: Add a warning


sticker in the appropriate language over the existing warning on the top of the
module.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

R1R6, UL type 12
For the UL type 12 enclosures, rubber plugs are required in the holes provided for
access to the drive mounting slots.
1. As required for access, remove the rubber plugs.
Push plugs out from the back of the drive.
2. R5 & R6: Align the sheet metal hood (not shown)
in front of the drives top mounting holes. (Attach
as part of next step.)

1, 3

3. Position the ACH550 onto the mounting screws


or bolts and securely tighten in all four corners.
Note: Lift the ACH550 by its metal chassis
(frame size R6 by the lifting holes on both sides
at the top).
FM

4. Re-install the rubber plugs.


5. Non-English speaking locations: Add a warning sticker in the appropriate language
over the existing warning on the top of the module.
R7R8
1. Use a hoist to move the cabinet into position.
Note: If the cabinet location does not provide access to the cabinet sides, be sure to
re-mount side panels before positioning cabinet.
2. Install and tighten mounting bolts.

5. Install wiring
WARNING! Ensure the motor is compatible for use with the ACH550. The ACH550
must be installed by a competent person. If in doubt, contact your local ABB sales or
service office.
Conduit kit
Wiring R1R6 drives with the UL type 1 Enclosure requires a conduit kit with the
following items:
conduit box
screws
cover
The kit is included with UL type 1 Enclosures.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

Connection diagrams
The following diagrams show:
The terminal layout for frame size R3, which, in general, applies to frame sizes
R1R6, except for the R5/R6 power and ground terminals.
The R5/R6 power and ground terminals.
The terminal layout for R7/R8.
R1R4 (Diagram shows the R3 frame.)
J1 DIP Switches for Analog Inputs
The switch is one of two types:
ON

Illustration of available switch


positions; not default settings

ON

AI1: (in Voltage Position)


AI2: (in Current Position)
Alternate

Original

Panel Connector

X1 Analog Inputs and Outputs


(and 10 V Ref. Voltage Output)

Power LED (Green)


Fault LED (Red)

X1 Digital Inputs
(and 24 V Aux. Voltage Output)
X1 Relay Outputs
Illustration of available switch
positions; not default settings
Optional Module 1

J2 DIP Switches
for RS485 Termination
J2

X1 Communications
(RS485)

J2
ON

Optional Module 2

ON

off position

Frame Sizes
R5/R6 differ.
See next page.

on position

Power Input
(U1, V1, W1)

Power Output to Motor


(U2, V2, W2)
EM3

EM1

GND
PE
X0003

Terminals Not Used

WARNING! To avoid danger, or damage to the drive, on IT systems and corner


grounded TN systems, see section Disconnecting the internal EMC filter on
page 10.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

R5

R6

F2

F1

F2

PE

GND
X0011

GND
Power Input
(U1, V1, W1)

Power Output to Motor


(U2, V2, W2)

F1

Terminals Not Used


Terminals Not Used

X0013

PE
Power Input
(U1, V1, W1)

GND
Power Output to Motor
(U2, V2, W2)

WARNING! To avoid danger, or damage to the drive, on IT systems and corner


grounded TN systems, see section Disconnecting the internal EMC filter on
page 10.

ACH550-UH

10

ACH550 Installation, Operation and Maintenance Manual

R7 (R8 Similar)
Motor
Terminals

Ground Lug
Bar

ACH550

Control Wires
(X1)

Input Power
Terminals

Terminal Strip
Only on
ACH550-UH

Disconnecting the internal EMC filter


On certain types of systems, you must disconnect the internal EMC filter, otherwise
the system will be connected to ground potential through the EMC filter capacitors,
which might cause danger, or damage the drive.
Note: When the internal EMC filter is disconnected, the drive is not EMC compatible.
The following table shows the installation rules for the EMC filter screws in order to
connect or disconnect the filter, depending on the system type and the frame size.
For more information on the different system types, see Floating networks on page
12 and Unsymmetrically grounded networks on page 11.
The locations of screws EM1 and EM3 are shown in the diagram on page 8. The
locations of screws F1 and F2 are shown in the diagram on page 9.
Frame
sizes
R1R3

R4

R5R6

Screw

Symmetrically
grounded TN systems
(TN-S systems)

Corner grounded
TN systems

IT systems (ungrounded
or high-resistancegrounded [> 30 ohm])

EM1

EM3

EM1

EM3

F1

F2

x = Install the screw. (EMC filter will be connected.)


= Replace the screw with the provided polyamide screw. (EMC filter will be disconnected.)
= Remove the screw. (EMC filter will be disconnected.)
EM1 and EM3 screws are M4 x 12
F1 and F2 screws are M4 x 16

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

11

Ground connections
For personnel safety, proper operation and to reduce electromagnetic emission/pickup, the drive and the motor must be grounded at the installation site.
Conductors must be adequately sized as required by safety regulations.
Power cable shields must be connected to the drive PE terminal in order to meet
safety regulations.
Power cable shields are suitable for use as equipment grounding conductors only
when the shield conductors are adequately sized as required by safety
regulations.
In multiple drive installations, do not connect drive terminals in series.
Unsymmetrically grounded networks
WARNING! Do not attempt to install or remove EM1 or EM3 screws while power is
applied to the drives input terminals.
Unsymmetrically grounded networks are defined in the following table. In such
networks, the internal connection provided by the EM3 screw (on frame sizes
R1R4 only) must be disconnected by removing EM3. If the grounding
configuration of the network is unknown, remove EM3.
Note: ACH550-UH drives are shipped with the screw removed (but included in the
conduit box).

Unsymmetrically Grounded Networks EM3 Must Be Out


Grounded at the
corner of the
delta

L1

Grounded at the
mid point of a
delta leg

L1

L2
L3

L2
L3
Single phase,
grounded at an
end point

L1

Three phase
Variac without
solidly grounded
neutral

L1
L1
L2

L2
L3
L3

ACH550-UH

12

ACH550 Installation, Operation and Maintenance Manual

EM3 (an M4x16 screw) makes an internal ground connection


that reduces electro-magnetic emission. Where EMC (electromagnetic compatibility) is a concern, and the network is
symmetrically grounded, EM3 may be installed. For
reference, the diagram at right illustrates a symmetrically
grounded network.

L1

L2
L3

Floating networks
WARNING! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drives input terminals.
For floating networks (also known as IT, ungrounded, or impedance/resistance
grounded networks):
Disconnect the ground connection to the internal RFI filters:
Frame sizes R1R4: Remove the EM1 screw (unit is shipped with EM3
removed, see Connection diagrams on page 8).
Frame sizes R5R6: Remove both the F1 and F2 screws (see page 9).
Where EMC requirements exist, check for excessive emission propagated to
neighboring low voltage networks. In some cases, the natural suppression in
transformers and cables is sufficient. If in doubt, use a supply transformer with
static screening between the primary and secondary windings.
Do NOT install an external RFI/EMC filter. Using an RFI filter grounds the input
power through the filter capacitors, which could be dangerous and could damage
the unit.
Checking motor and motor cable insulation
WARNING! Check the motor and motor cable insulation before connecting the drive
to input power. For this test, make sure that motor cables are NOT connected to the
drive.
1. Complete motor cable connections to the motor, but NOT to the drive output
terminals (U2, V2, W2).
2. At the drive end of the motor cable, measure the insulation
resistance between each motor cable phase and Protective
Earth (PE): Apply a voltage of 1 kV DC and verify that
resistance is greater than 1 Mohm.

ACH550-UH

M
ohm
PE

ACH550 Installation, Operation and Maintenance Manual

13

R1R6, wiring UL type 1 enclosure


1. Open the appropriate knockouts in the
conduit box. (See Conduit kit on page 7.)
2. Install thin-wall conduit clamps (not supplied).

X0007

3. Install conduit box.


4. Connect conduit runs for input power, motor
and control cables to the box.

X0005

5. Route input power and motor wiring through


separate conduits.

6. Strip wires.
7. Connect power, motor, and ground wires to
the drive terminals.

7
5
4

IP2004

Note: For R5 frame size, the minimum power cable size is 25 mm2 (4 AWG). For R6
frame size, refer to Power terminal considerations R6 Frame size on page 16.
8. Route the control cables through the conduit
(not the same conduit as either input power or
motor wiring).
9. Use available secure points and tie strap
landings to permanently secure control wiring
at a minimum distance of 6 mm (1/4") from
power wiring.

10
12

10. Strip the control cable sheathing and twist the


copper screen into a pig-tail.
11. Connect the ground screen pig-tail for digital
and analog I/O cables at X1-1. (Ground only
at drive end.)

12. Connect the ground screen pig-tail for RS485


cables at X1-28 or X1-32. (Ground only at
drive end.)

IP2005

13. Strip and connect the individual control wires to the drive terminals.
14. Install the conduit box cover (1 screw).

ACH550-UH

14

ACH550 Installation, Operation and Maintenance Manual

R1R6, wiring UL type 12 enclosure


1. Step depends on Frame Size:
Frame Sizes R1R4: Remove and discard the
cable seals where conduit will be installed. (The
cable seals are cone-shaped, rubber seals on
the bottom of the drive.)
Frame Sizes R4 and R5: Use punch to create
holes for conduit connections as needed.

R1R4

IP5013

R5, R6 1

IP5023

2. For each conduit run (input power, motor and


control wiring must be separate), install water tight
conduit connectors (not supplied).
2

IP5006

3. Route the power wiring through conduit.


4. Route the motor wiring through conduit (not the
same conduit as input power wiring run).

5. Strip the wires.


6. Connect the power, motor, and ground wires to
the drive terminals.

4
IP5007

Note: For R5 frame size, the minimum power cable size is 25 mm2 (4 AWG). For R6
frame size, refer to Power terminal considerations R6 Frame size on page 16.
7. Route the control cables through the conduit (not
the same conduit as either input power or motor
wiring runs).
8. Use available secure points and tie strap landings to 911
permanently secure control wiring at a minimum
distance of 6 mm (1/4") from power wiring.
9. Strip the control cable sheathing and twist the
copper screen into a pig-tail.
10. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
end.)
11. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
7
12. Strip and connect the individual control wires to the drive
terminals.
13. Install the conduit box cover (1 screw).

ACH550-UH

IP5008

ACH550 Installation, Operation and Maintenance Manual

15

R7R8, wiring (both enclosure types)


The figures show connections in the R7 cabinet, the R8 cabinet is similar.
1. Remove the conduit connection plate from the top of the left bay.
2. Route the input power, motor and control
cables to the top of the cabinet. Each cable
type (input power, motor, and control) must
be in separate conduit.
3. Use punch to create holes for conduit
connections as needed.
4. UL type 12 Enclosure: For each conduit
run (input power, motor and control wiring
must be separate), install water tight
conduit connectors (not supplied).

Gnd
Input Power
Cable

Terminal Strip
Only on
ACH550-UH

BP0054

5. Connect input power and motor cables to


the bus terminals.
6. Connect grounds to ground bar.
7. Use available secure points and tie strap
landings to permanently secure control
wiring at a minimum distance of 6 mm
(1/4") from power wiring.

Gnd
Motor
Cable

8. Strip the control cable sheathing and twist


the copper screen into a pig-tail.
9. Connect the ground screen pig-tail for
digital and analog I/O cables at X1-1.
(Ground only at drive end.)
10. Connect the ground screen pig-tail for
RS485 cables at X1-28 or X1-32. (Ground
only at drive end.)

BP0054

11. Strip and connect the individual control wires to the drive terminals.

ACH550-UH

16

ACH550 Installation, Operation and Maintenance Manual

Drives power connection terminals


The following table provides specifications for the drives power connection
terminals.
U1, V1, W1
U2, V2, W2
BRK+, UDC+ Terminals

Frame
Size

Min. Wire Size

Earthing PE Terminal

Max. Wire Size


2

Torque

Max. Wire Size


2

Torque

mm2

AWG

mm

AWG

Nm

lb-ft

mm

AWG

Nm

lb-ft

R1Note 1

0.75

18

16

1.3

16

1.3

Note 1

R2

0.75

18

16

1.3

16

1.3

R3Note 1

2.5

14

25

2.7

25

2.7

R4Note 1

10

50

1/0

5.6

50

1/0

5.6

R5

16

70

2/0

15

11

70

2/0

15

11

R6

95Note 2

3/0

185

350 MCM

40

30

185

350 MCM

40

30

R7

16

185

350 MCM

40

30

R8

16

2x240 2x500 MCM

57

42

Attach appropriate ring lugs to


ground wires and mount with,
up to five 13/32 bolts.

1. Do not use aluminum cable with frame sizes R1R4.


2. See the following section for smaller wire sizes on frame size R6.

Power terminal considerations R6 Frame size


WARNING! For R6 power terminals, if compression lugs are supplied, they can only
be used for wire sizes that are 95 mm2 (3/0 AWG) or larger. Smaller wires will loosen
and may damage the drive, and require ring lugs as described below.
On the R6 frame size, if the cable size used is less than 95 mm2 (3/0 AWG) or if no
compression lugs are supplied, use ring lugs.
Drives control connection terminals
The following table provides specifications for the drives control terminals
Frame Size

Control
Maximum Wire Size
2

All

Torque

mm

AWG

Nm

lb-ft

1.5

16

0.4

0.3

Control terminal descriptions


The following full-page diagram provides a general description of the control
terminals on the drive.
Note: Terminals 3, 6, and 9 are at the same potential.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

17

Note: For safety reasons the fault relay signals a fault when the ACH550 is
powered down.
X1

Drive Control Terminal Description

SCR

Terminal for signal cable screen. (Connected internally to chassis ground.)

AI1

Analog input channel 1, programmable. Default2 = external reference. Resolution


0.1%, accuracy 1%.
ON

J1:AI1 OFF: 0(2)10 V (Ri = 312 k)

Analog I/O

AGND

Analog input circuit common (connected internally to chassis gnd. through 1 M).

+10 V

Potentiometer reference source: 10 V 2%, max. 10 mA (1k < R < 10k).

AI2

Analog input channel 2, programmable. Default2 = PID feedback. Resolution 0.1%,


accuracy 1%.
J1:AI2 OFF: 0(2)10 V (Ri = 312 k)

ON

ON

J1:AI2 ON: 0(4)20 mA (Ri = 100 )

ON

Digital Inputs1

ON

for ON

or, for OFF

ON

for ON
1

AGND

Analog input circuit common (connected internally to chassis gnd. through 1 M).

AO1

Analog output, programmable. Default2 = frequency. 020 mA (load < 500 ).

AO2

Analog output, programmable. Default2 = current. 020 mA (load < 500 ).

AGND

Analog output circuit common (connected internally to chassis gnd. through 1 M).

10 +24V

Auxiliary voltage output 24 VDC / 250 mA (reference to GND), short circuit


protected.

11

Auxiliary voltage output common (connected internally as floating).

GND

12 DCOM

Digital input common. To activate a digital input, there must be +10 V


(or -10 V) between that input and DCOM. The 24 V may be provided by the
ACH550 (X1-10) or by an external 1224 V source of either polarity.

13 DI1

Digital input 1, programmable. Default2 = start/stop.

14 DI2

Digital input 2, programmable. Default2 = not configured.

15 DI3

Digital input 3, programmable. Default2 = constant (preset) speed.

16 DI4

Digital input 4, programmable. Default2 = safety interlock.

17 DI5

Digital input 5, programmable. Default2 = not configured.

18 DI6

Digital input 6, programmable. Default2 = not configured.

19 RO1C
20 RO1A
Relay Outputs

ON

J1:AI1 ON: 0(4)20 mA (Ri = 100 )

ON

or, for OFF

Relay output 1, programmable. Default2 = Ready


Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

21 RO1B
22 RO2C
23 RO2A

Relay output 2, programmable. Default2 = Running


Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

24 RO2B
25 RO3C
26 RO3A

Relay output 3, programmable. Default2 = Fault (-1)


Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)

27 RO3B
1
2

Digital input impedance 1.5 k. Maximum voltage for digital inputs is 30 V.


Default values depend on the macro used. Values specified are for the HVAC default macro.

ACH550-UH

18

ACH550 Installation, Operation and Maintenance Manual

You can wire the digital input terminals in either a PNP or NPN configuration.
PNP connection (source)
X1
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6

NPN connection (sink)


X1
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6

Serial communications
Terminals 2832 provide RS485 serial communication connections used to control
or monitor the drive from a fieldbus controller.
6. Check installation
Before applying power, perform the following checks.
Check
Installation environment conforms to the drives specifications for ambient conditions.
The drive is mounted securely.
Space around the drive meets the drives specifications for cooling.
The motor and driven equipment are ready for start.
For floating networks (R1R6): The internal RFI filter is disconnected (screws EM1 & EM3 or
F1 & F2).
The drive is properly grounded.
The input power voltage matches the drive nominal input voltage range.
The input power connections at U1, V1, and W1 are connected and tightened as specified.
The input power branch circuit protection is installed.
The motor connections at U2, V2, and W2 are connected and tightened as specified.
The input power, motor and control wiring are routed through separate conduit runs.
NO power factor compensation capacitors are in the motor cable.
The control connections are connected and tightened as specified.
NO tools or foreign objects (such as drill shavings) are inside the drive.
NO alternate power source for the motor (such as a bypass connection) is connected no
voltage is applied to the output of the drive.

7. Re-install cover

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

19

8. Apply power
Always re-install the covers before turning power on.
WARNING! The ACH550 will start up automatically at power up, if the external run
command is on.
Apply input power. When power is applied to the ACH550, the green LED comes on.
Note: Before increasing motor speed, check that the motor is running in the desired
direction. To change rotation direction, switch motor leads as shown below.

Drive
U1

V1

W1

GND

U2

V2

W2

L1
Motor

Input L2
L3
GND
To change rotation direction,
switch motor leads

Drive
U1

V1

W1

GND

U2

V2

W2

L1
Input L2
L3
GND

Motor
FM

9. Before Start-up
The ACH550 has default parameter settings that are sufficient for many situations.
However, review the following situations. Perform the associated procedures as
appropriate.
Spin motor
When first installed and started the control panel displays a welcome screen with the
following options.
Press Exit to commission the drive as described in section Start-up by changing
the parameters individually on page 23.
Press Enter to move to the following options:
Select Commission Drive to commission the drive as described in section
Start-Up by Start-up by using the Start-Up Assistant on page 23.
Select Spin Motor to operate the motor prior to commissioning. This option

ACH550-UH

20

ACH550 Installation, Operation and Maintenance Manual

operates the motor without any commissioning, except entry of the motor data
as described below. Spin Motor is useful, for example, to operate ventilation
fans prior to commissioning.
Note: When using Spin Motor, the motor speed is limited to the range 1/32/3 of
maximum speed. Also, no interlocks are activated. Finally, once the drive is
commissioned, the welcome screen and this option no longer appear.
Motor data
The motor data on the ratings plate may differ from the defaults in the ACH550. The
drive provides more precise control and better thermal protection if you enter the
rating plate data.
1. Gather the following from the motor ratings plate:
Voltage
Nominal motor current
Nominal frequency
Nominal speed
Nominal power
2. Edit parameters 99059909 to the correct values.
Assistant Control Panel: The Start-Up Assistant walks you through this data entry.
Basic Control Panel: Refer to ACH550 Users Manual, for parameter editing
instructions.
Fault and alarm adjustments
The ACH550 can detect a wide variety of potential system problems. For example,
initial system operation may generate faults or alarms that indicate set-up problems.
1. Faults and alarms are reported on the control panel with a number. Note the number
reported.
2. Review the description provided for the reported fault/alarm:
Use the fault and alarm listings on pages 24 and 29 respectively, or
Press the help key (Assistant Control Panel only) while fault or alarm is displayed.
3. Adjust the system or parameters as appropriate.

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ACH550 Installation, Operation and Maintenance Manual

21

Operation
The ACH550 HVAC control panel (ACS-CP-B) features:
Status LED
(Green when normal,
if flashing or red,
see Diagnostics.)
UP

SOFT
KEY 2

SOFT
KEY 1
DOWN

HELP (always available)

AUTO
OFF

HAND

X0201

General display features


Soft key functions
The soft key functions are defined by text displayed just above each key.
Display contrast
To adjust display contrast, simultaneously press
appropriate.

and

or

, as

HVAC control panel modes


The HVAC control panel has several different modes for configuring, operating and
diagnosing the drive. To reach the Standard Display Mode, press EXIT until the LCD
display shows status information. Select MENU and use UP/DOWN buttons to select
other modes. The modes are:
Standard Display Mode Shows drive status information and operates the drive.
Parameters Mode Edits parameter values individually.
Start-up Assistant Mode Guides the start-up and configuration.
Changed Parameters Mode Shows changed parameters.
Fault Logger Mode Shows the drive fault history.
Drive Parameter Backup Mode Stores or uploads the parameters.
Clock Set Mode Sets the time and date for the drive.
I/O Settings Mode Checks and edits the I/O settings.
Alarm Mode Reporting mode triggered by drive alarms.

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ACH550 Installation, Operation and Maintenance Manual

Operating the drive


AUTO/HAND The very first time the drive is powered up, it is in the auto control
(AUTO) mode, and is controlled from the Control terminal block X1.
To switch to hand control (HAND) and control the drive using the control panel, press
and hold the
or
button.
Pressing the HAND button switches the drive to hand control while keeping the
drive running.
Pressing the OFF button switches to hand control and stops the drive.
To switch back to auto control (AUTO), press and hold the

button.

Hand/Auto/Off To start the drive press the HAND or AUTO buttons, to stop the
drive press the OFF button.
Reference To modify the reference (only possible if the display in the upper right
corner is in reverse video) press the UP or DOWN buttons (the reference changes
immediately).
The reference can be modified in the local control mode (HAND/OFF), and can be
parameterized (using Group 11 reference select) to also allow modification in the
remote control mode.
Note: The Start/Stop, Shaft direction and Reference functions are only valid in local
control (HAND/OFF) mode.

Start-up by using the Start-Up Assistant


To start the Start-Up Assistant, follow these steps:
Select MENU to enter the main menu.
1

Select ASSISTANTS with the Up/Down


buttons and select ENTER.
2

Scroll to COMMISSION DRIVE with the


Up/Down buttons.
3

Change the values suggested by the


assistant to your preferences and then
press SAVE after every change.

The Start-Up Assistant will guide you through the start-up.

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ACH550 Installation, Operation and Maintenance Manual

23

Start-up by changing the parameters individually


To change the parameters, follow these steps:
Select MENU to enter the main menu.
1

Select the Parameters mode with the UP/


DOWN buttons and select ENTER to
select the Parameters mode.

Select the appropriate parameter group


with the UP/DOWN buttons and select
SEL

Select the appropriate parameter in a


group with the UP/DOWN buttons. Select
EDIT to change the parameter value.

Press the UP/DOWN buttons to change


the parameter value.
5

Select SAVE to store the modified value or


select CANCEL to leave the set mode.
Any modifications not saved are
cancelled.
Select EXIT to return to the listing of
parameter groups, and again to return to
the main menu.

Complete the control connections by manually entering the parameters.


Note: The current parameter value appears below the highlighted parameter. To
view the default parameter value, press the UP/DOWN buttons simultaneously. To
restore the default factory settings, select the application macro HVAC Default.

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ACH550 Installation, Operation and Maintenance Manual

Diagnostics
Fault listing

ACH550-UH

Fault
Code

Fault Name In
Panel

OVERCURRENT

Output current is excessive. Check for and correct:


Excessive motor load.
Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and
2205 ACCELER TIME 2).
Faulty motor, motor cables or connections.
Output disconnect device not interlocked.
Interaction with external input filter.

DC OVERVOLT

Intermediate circuit DC voltage is excessive. Check for and correct:


Static or transient overvoltages in the input power supply.
Insufficient deceleration time (parameters 2203 DECELER TIME 1 and
2206 DECELER TIME 2).
Verify that overvoltage controller is ON (using parameter 2005).
Interaction with external input filter.

DEV OVERTEMP

Drive heatsink is overheated. Temperature is at or above limit.


R1R4 & R7/R8: 115 C (239 F)
R5/R6: 125 C (257 F)
Check for and correct:
Fan failure.
Obstructions in the air flow.
Dirt or dust coating on the heat sink.
Excessive ambient temperature.
Excessive motor load.

SHORT CIRC

Fault current. Check for and correct:


A short-circuit in the motor cable(s) or motor.
Supply disturbances.

RESERVED

Not used.

DC UNDERVOLT

Intermediate circuit DC voltage is not sufficient. Check for and correct:


Missing phase in the input power supply.
Blown fuse.
Undervoltage on mains.

AI1 LOSS

Analog input 1 loss. Analog input value is less than AI1FLT LIMIT (3021).
Check for and correct:
Source and connection for analog input.
Parameter settings for AI1FLT LIMIT (3021) and 3001 AI<MIN FUNCTION.

AI2 LOSS

Analog input 2 loss. Analog input value is less than AI2FLT LIMIT (3022).
Check for and correct:
Source and connection for analog input.
Parameter settings for AI2FLT LIMIT (3022) and 3001 AI<MIN FUNCTION.

Description and Recommended Corrective Action

ACH550 Installation, Operation and Maintenance Manual

25

Fault
Code

Fault Name In
Panel

MOT TEMP

Motor is too hot, based on either the drives estimate or on temperature


feedback.
Check for overloaded motor.
Adjust the parameters used for the estimate (30053009).
Check the temperature sensors and Group 35 parameters.

10

PANEL LOSS

Panel communication is lost and either:


Drive is in local control mode (the control panel displays HAND or OFF),
or
Drive is in remote control mode (AUTO) and is parameterized to accept
start/stop, direction or reference from the control panel.
To correct check:
Communication lines and connections
Parameter 3002 PANEL COMM ERROR.
Parameters in Group 10: START/STOP/DIR and Group 11:
REFERENCE SELECT (if drive operation is AUTO).

11

ID RUN FAIL

The motor ID run was not completed successfully. Check for and correct:
Motor connections
Motor parameters 99059909 do not match motor nameplate.

12

MOTOR STALL

Motor or process stall. Motor is operating in the stall region. Check for and
correct:
Excessive load.
Insufficient motor power.
Parameters 30103012.

14

EXTERNAL FLT

1 Digital input defined to report first external fault is active. See parameter
3003 EXTERNAL FAULT 1.

15

EXTERNAL FLT

2 Digital input defined to report second external fault is active. See parameter
3004 EXTERNAL FAULT 2.

16

EARTH FAULT

Possible ground fault detected in the motor or motor cables. The drive
monitors for ground faults while the drive is running and while the drive is
not running. Detection is more sensitive when the drive is not running and
can produce false positives.
Possible corrections:
Check for/correct faults in the input wiring.
Verify that motor cable does not exceed maximum specified length.
A delta grounded input power supply and motor cables with high
capacitance may result in erroneous error reports during non-running
tests. To disable response to fault monitoring when the drive is not
running, use parameter 3023 WIRING FAULT. To disable response to all
ground fault monitoring, use parameter 3017 EARTH FAULT.

17

UNDERLOAD

Motor load is lower than expected. Check for and correct:


Disconnected load.
Group 37: USER LOAD CURVE.

18

THERM FAIL

Internal fault. The thermistor measuring the internal temperature of the


drive is open or shorted. Contact your local ABB sales representative.

19

OPEX LINK

Internal fault. A communication-related problem has been detected on the


fiber optic link between the OITF and OINT boards. Contact your local ABB
sales representative.

20

OPEX PWR

Internal fault. Low voltage condition detected on OINT power supply.


Contact your local ABB sales representative.

Description and Recommended Corrective Action

ACH550-UH

26

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

Fault
Code

Fault Name In
Panel

21

CURR MEAS

Internal fault. Current measurement is out of range. Contact your local ABB
sales representative.

22

SUPPLY PHASE

Ripple voltage in the DC link is too high. Check for and correct:
Missing mains phase.
Blown fuse.
Interaction with external input filter. Set parameter 2619 to ON.

23

ENCODER ERR

Not used (Available only with encoder and parameter Group 50).

23

ENCODER ERR

The drive is not detecting a valid encoder signal. Check for and correct:
Encoder presence and proper connection (reverse wired, loose
connection, or short circuit).
Voltage logic levels are outside of the specified range.
A working and properly connected Pulse Encoder Interface Module,
OTAC-01.
Wrong value entered in parameter 5001 PULSE NR. A wrong value will
only be detected if the error is such that the calculated slip is greater
than 4 times the rated slip of the motor.
Encoder is not being used, but parameter 5002 ENCODER ENABLE = 1
(ENABLED).

24

OVERSPEED

Motor speed is greater than 120% of the larger (in magnitude) of 2001
MINIMUM SPEED or 2002 MAXIMUM SPEED. Check for and correct:
Parameter settings for 2001 and 2002.
Adequacy of motor braking torque.
Applicability of torque control.
Brake chopper and resistor.

25

RESERVED

Not used as of the publication of this manual.

26

DRIVE ID

Internal fault. Configuration Block Drive ID is not valid. Contact your local
ABB sales representative.

27

CONFIG FILE

Internal configuration file has an error. Contact your local ABB sales
representative.

28

SERIAL

29

EFB CONFIG
FILE

Error in reading the configuration file for the embedded fieldbus.

30

FORCE TRIP

Fault trip forced by the fieldbus. See the fieldbus Users Manual.

31

EFB

32

EFB

33

EFB

34

MOTOR PHASE

1 ERR

Description and Recommended Corrective Action

Fieldbus communication has timed out. Check for and correct:


Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME).
Communication settings (Group 51 or 53 as appropriate).
Poor connections and/or noise on line.

Fault code reserved for the embedded fieldbus (EFB) protocol application.
These codes are not used as of the publication of this manual.

Fault in the motor circuit. One of the motor phases is lost. Check for and
correct:
Motor fault.
Motor cable fault.
Thermal relay fault (if used).
Internal fault.

ACH550 Installation, Operation and Maintenance Manual

27

Fault
Code

Fault Name In
Panel

35

OUTPUT WIRING

Possible power wiring error detected. When the drive is not running it
monitors for an improper connection between the drive input power and the
drive output. Check for and correct:
Proper input wiring line voltageis NOT connected to drive output.
The fault can be erroneously declared if the input power is a delta
grounded system and motor cable capacitance is large. This fault can be
disabled using parameter 3023 WIRING FAULT.

36

INCOMP
SWTYPE

The drive cannot use the software.


Internal Fault.
The loaded software is not compatible with the drive.
Call support representative.

37

CB OVERTEMP

Drive control board is overheated.


Check for and correct:
Excessive ambient temperatures
Fan failure.
Obstructions in the air flow.

101

SERF CORRUPT

102

RESERVED

Error internal to the drive. Contact your local ABB sales representative and
report the error number.

103

SERF MACRO

104

RESERVED

105

RESERVED

201

DSP T1
OVERLOAD

202

DSP T2
OVERLOAD

203

DSP T3
OVERLOAD

204

DSP STACK
ERROR

205

RESERVED

Description and Recommended Corrective Action

Error in the system. Contact your local ABB sales representative and report
the error number.

(obsolete)
206

OMIO ID ERROR

207

EFB LOAD ERR

1000

PAR HZRPM
LIMITS

Parameter values are inconsistent. Check for any of the following:


2001 MINIMUM SPEED > 2002 MAXIMUM SPEED.
2007 MINIMUM FREQ > 2008 MAXIMUM FREQ.
2001 MINIMUM SPEED / 9908 MOTOR NOM SPEED is outside proper range
(> 50)
2002 MAXIMUM SPEED / 9908 MOTOR NOM SPEED is outside proper range
(> 50)
2007 MINIMUM FREQ / 9907 MOTOR NOM FREQ is outside proper range
(> 50)
2008 MAXIMUM FREQ / 9907 MOTOR NOM FREQ is outside proper range
(> 50)

1001

PAR PFAREFNG

Parameter values are inconsistent. Check for the following:


2007 MINIMUM FREQ is negative, when 8123 PFA ENABLE is active.

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ACH550 Installation, Operation and Maintenance Manual

Fault
Code
1002

Fault Name In
Panel

Description and Recommended Corrective Action

RESERVED

(Obsolete)
1003

PAR AI SCALE

Parameter values are inconsistent. Check for any of the following:


1301 AI 1 MIN > 1302 AI 1 MAX.
1304 AI 2 MIN > 1305 AI 2 MAX.

1004

PAR AO SCALE

Parameter values are inconsistent. Check for any of the following:


1504 AO 1 MIN > 1505 AO 1 MAX.
1510 AO 2 MIN > 1511 AO 2 MAX.

1005

PAR PCU

1006

EXT ROMISSING

Parameter values are inconsistent. Check for the following:


Extension relay module not connected and
14101412 RELAY OUTPUTS 46 have non-zero values.

1007

PAR
FBUSMISSING

Parameter values are inconsistent. Check for and correct:


A parameter is set for fieldbus control (e.g. 1001 EXT1 COMMANDS = 10
(COMM)), but 9802 COMM PROT SEL = 0.

1008

PAR
PFAWOSCALAR

Parameter values are inconsistent 9904 MOTOR CTRL MODE must be = 3


(SCALAR: SPEED), when 8123 PFA ENABLE is activated.

1009

PAR PCU1

Parameter values for power control are inconsistent: Improper motor


nominal frequency or speed. Check for both of the following:
1 < (60 * 9907 MOTOR NOM FREQ / 9908 MOTOR NOM SPEED < 16
0.8 < 9908 MOTOR NOM SPEED /
(120 * 9907 MOTOR NOM FREQ / Motor Poles) < 0.992

1010

PAR PFA
OVERRIDE

Both the override mode and PFA are activated at the same time. These
modes are mutually incompatible, because PFA interlocks cannot be
observed in the override mode.

1011

PAR OVERRIDE
PARS

Overeride is enabled, but parameters are incompatible. Verify that 1701 is


not zero, and (depending on 9904 value) 1702 or 1703 is not zero.

1012

PAR PFA IO

IO configuration is not complete not enough relays are parameterized to


PFA. Or, a conflict exists between Group 14, parameter 8117, NR OF AUX
MOT, and parameter 8118, AUTOCHNG INTERV.

1013

PAR PFA IO

IO configuration is not complete the actual number of PFA motors


(parameter 8127, MOTORS) does not match the PFA motors in Group 14 and
parameter 8118 AUTOCHNG INTERV.

1014

PAR PFA IO

IO configuration is not complete the drive is unable to allocate a digital


input (interlock) for each PFA motor (parameters 8120 INTERLOCKS and
8127 MOTORS).

Parameter values for power control are inconsistent: Improper motor


nominal kVA or motor nominal power. Check for the following:
1.1 < (9906 MOTOR NOM CURR * 9905 MOTOR NOM VOLT * 1.73 / PN) < 3.0
Where: PN = 1000 * 9909 MOTOR NOM POWER (if units are kW)
or PN = 746 * 9909 MOTOR NOM POWER (if units are HP, e.g. in US)

Fault history
For reference, the last three fault codes are stored into parameters 0401, 0412,
0413. For the most recent fault (identified by parameter 0401), the drive stores
additional data (in parameters 04020411) to aid in troubleshooting a problem. For
example, parameter 0404 stores the motor speed at the time of the fault.

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ACH550 Installation, Operation and Maintenance Manual

29

To clear the fault history (all of the Group 04, Fault History parameters):
1. Using the control panel in Parameters mode, select parameter 0401.
2. Press EDIT.
3. Press UP and Down simultaneously.
4. Press SAVE.
Alarm listing
The following table lists the alarms by code number and describes each.
Alarm
Code

Display

Description

2001

OVERCURRENT

Current limiting controller is active. Check for and correct:


Excessive motor load.
Insufficient acceleration time (parameters 2202 ACCELER TIME 1 and
2205 ACCELER TIME 2).
Faulty motor, motor cables or connections.
Output disconnect device not interlocked.
Interaction with external input filter.

2002

OVERVOLTAGE

Over voltage controller is active. Check for and correct:


Static or transient overvoltages in the input power supply.
Insufficient deceleration time (parameters 2203 DECELER TIME 1 and
2206 DECELER TIME 2).
Interaction with external input filter.

2003

UNDERVOLTAGE

Under voltage controller is active. Check for and correct:


Undervoltage on mains.

2004

DIR LOCK

The change in direction being attempted is not allowed. Either:


Do not attempt to change the direction of motor rotation, or
Change parameter 1003 DIRECTION to allow direction change (if
reverse operation is safe).

2005

I/O COMM

Fieldbus communication has timed out. Check for and correct:


Fault setup (3018 COMM FAULT FUNC and 3019 COMM FAULT TIME).
Communication settings (Group 51 or 53 as appropriate).
Poor connections and/or noise on line.

2006

AI1 LOSS

Analog input 1 is lost, or value is less than the minimum setting.


Check:
Input source and connections
Parameter that sets the minimum (3021)
Parameter that sets the Alarm/Fault operation (3001)

2007

AI2 LOSS

Analog input 2 is lost, or value is less than the minimum setting.


Check:
Input source and connections
Parameter that sets the minimum (3022)
Parameter that sets the Alarm/Fault operation (3001)

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ACH550 Installation, Operation and Maintenance Manual

Alarm
Code

Description

2008

PANEL LOSS

Panel communication is lost and either:


Drive is in local control mode (the control panel displays HAND or
OFF), or
Drive is in remote control mode (AUTO) and is parameterized to
accept start/stop, direction or reference from the control panel.
To correct check:
Communication lines and connections
Parameter 3002 PANEL LOSS.
Parameters in Groups 10 START/STOP/DIR and 11: REFERENCE
SELECT (if drive operation is AUTO).

2009

DEVICE
OVERTEMP

Drive heatsink is hot. This alarm warns that a DEVICE OVERTEMP fault
may be near.
R1R4 & R7/R8: 100 C (212 F)
R5/R6: 110 C (230 F)
Check for and correct:
Fan failure.
Obstructions in the air flow.
Dirt or dust coating on the heat sink.
Excessive ambient temperature.
Excessive motor load.

2010

MOT OVERTEMP

Motor is hot, based on either the drives estimate or on temperature


feedback. This alarm warns that a Motor Underload fault trip may be
near. Check:
Check for overloaded motor.
Adjust the parameters used for the estimate (30053009).
Check the temperature sensors and Group 35 parameters.

2011

UNDERLOAD

Motor load is lower than expected. This alarm warns that a Motor
Underload fault trip may be near. Check:
Motor and drive ratings match (motor is NOT undersized for the
drive)
Settings Group 37: USER LOAD CURVE

MOTOR STALL

Motor is operating in the stall region. This alarm warns that a Motor
Stall fault trip may be near.

2013
(note 1)

AUTORESET

This alarm warns that the drive is about to perform an automatic fault
reset, which may start the motor.
To control automatic reset, use parameter Group 31: AUTOMATIC
RESET.

2014
(note 1)

AUTOCHANGE

This alarm warns that the PFA autochange function is active.


To control PFA, use parameter Group 81: PFA CONTROL

2015

PFA INTERLOCK

This alarm warns that the PFA interlocks are active, which means that
the drive cannot start the following:
Any motor (when Autochange is used),
The speed regulated motor (when Autochange is not used).

2016

Reserved

2017

OFF BUTTON

Note 1.

2018
(note 1)

PID SLEEP

This alarm warns that the PID sleep function is active, which means
that the motor could accelerate when the PID sleep function ends.
To control PID sleep, use parameters 40224026 or 41224126.

2012

ACH550-UH

Display

ACH550 Installation, Operation and Maintenance Manual

Alarm
Code

Display

31

Description

2019

ID RUN

Performing ID run.

2020

OVERRIDE

This alarm warns that the Override function is active, which may start
the motor.

2021

START ENABLE
MISSING

This alarm warns that the Start Enable 1 signal is missing.


To control Start Enable 1 function, use parameter 1608.
To correct, check:
Digital input configuration.
Communication settings.

2022

START ENABLE
MISSING

This alarm warns that the Start Enable 2 signal is missing.


To control Start Enable 2 function, use parameter 1609.
To correct, check:
Digital input configuration.
Communication settings.

2023

EMERGENCY
STOP

Emergency stop activated.

2024

ENCODER ERROR

The drive is not detecting a valid encoder signal. Check for and
correct:
Encoder presence and proper connection (reverse wired, loose
connection, or short circuit).
Voltage logic levels are outside of the specified range.
A working and properly connected Pulse Encoder Interface Module,
OTAC-01.
Wrong value entered in parameter 5001 PULSE NR. A wrong value
will only be detected if the error is such that the calculated slip is
greater than 4 times the rated slip of the motor.
Encoder is not being used, but parameter 5002 ENCODER ENABLE =
1 (ENABLED).

2025

FIRST START

Signals that a the drive is performing a First Start evaluation of motor


characteristics. This is normal the first time the motor is run after motor
parameters are entered or changed. See parameter 9910 (MOTOR ID
RUN) for a description of motor models.

2026

RESERVED

Not used.

2027

USER LOAD
CURVE

This alarm warns that the condition defined by parameter 3701 USER
LOAD C MODE has been valid longer that half of the time difined by 3703
USER LOAD C TIME.

2028

START DELAY

Shown during the Start delay. See parameter 2113 START DELAY.

Note 1. Even when the relay output is configured to indicate alarm conditions (e.g. parameter
1401 RELAY OUTPUT 1 = 5 (ALARM) or 16 (FLT/ALARM)), this alarm is not indicated by a relay output.

Maintenance
Warning! Read Safety on page 2 before performing any maintenance on the
equipment. Ignoring the safety instructions can cause injury or death.

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ACH550 Installation, Operation and Maintenance Manual

Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance

Application

Interval

Instruction

Check/replace R7/R8
enclosure inlet air filter

R7/R8 UL type 12
enclosures

Check every 3
months. Replace as
needed.

Frame Sizes R7/R8 UL


type 12 enclosure inlet air
filter on page 35

Check/replace R7/R8
enclosure exhaust air
filter.

R7/R8 UL type 12
enclosures

Check every 6
months. Replace as
needed.

Frame Sizes R7/R8 UL


type 12 enclosure exhaust
filters on page 37

Check and clean


heatsink.

All

Depends on the
dustiness of the
environment (every
612 months)

See Heatsink below.

Replace drive module


fan.

All

Every six years

See Drive module fan


replacement on page 33.

Replace enclosure fan.

UL type 12
enclosures

Every three years.

See Enclosure fan


replacement UL Type 12
enclosures on page 34.

Change capacitor.

Frame sizes R5,


R6 and R8

Every ten years

See Capacitors on
page 38.

Replace battery in the


Assistant control panel

All

Every ten years

See Control panel on


page 38.

Heatsink
The heatsink fins accumulate dust from the cooling air. Since a dusty heatsink is less
efficient at cooling the drive, overtemperature faults become more likely. In a
normal environment (not dusty, not clean) check the heatsink annually, in a dusty
environment check more often.
Clean the heatsink as follows (when necessary):
1. Remove power from drive.
2. Remove the cooling fan (see section Drive module fan replacement on page 33).
3. Blow clean compressed air (not humid) from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of the dust entering adjoining equipment, perform the cleaning
in another room.
4. Replace the cooling fan.
5. Restore power.

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ACH550 Installation, Operation and Maintenance Manual

33

Drive module fan replacement


The drive module fan cools the heatsink. Fan failure can be predicted by the
increasing noise from fan bearings and the gradual rise in the heatsink temperature
in spite of heatsink cleaning. If the drive is operated in a critical part of a process, fan
replacement is recommended once these symptoms start appearing. Replacement
fans are available from ABB. Do not use other than ABB specified spare parts.
To monitor the running time of the cooling fan, see Group 29: MAINTENANCE TRIG
instructions.
Frame Sizes R1R4
To replace the fan:

1. Remove power from drive.


4

2. Remove drive cover.


3. For Frame Size:

R1, R2: Press together the retaining clips on the fan


cover sides, and lift.
R3, R4: Press in on the lever located on the left side
of the fan mount, and rotate the fan up and out.
4. Disconnect the fan cable.
5. Install the fan in reverse order.

X0021

6. Restore power.
Frame Sizes R5 and R6

Bottom View (R5)

To replace the fan:


3

1. Remove power from drive.

2. Remove the screws attaching the fan.


3. Remove the fan:

X5023

R5: Swing the fan out on its hinges.

Bottom View (R6)

R6: Pull the fan out.


4. Disconnect the fan cable.
5. Install the fan in reverse order.

6. Restore power.
X0022

Frame Sizes R7 and R8


Refer to the installation instructions supplied with the fan kit.

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ACH550 Installation, Operation and Maintenance Manual

Enclosure fan replacement UL Type 12 enclosures


UL type 12 enclosures include an additional fan (or fans) to move air through the
enclosure.
Frame Sizes R1 to R4
To replace the internal enclosure fan in frame sizes R1 to R4:
1. Remove power from drive.
2. Remove the front cover.

4
3

3. The housing that holds the fan in place has barbed


retaining clips at each corner. Press all four clips toward
the center to release the barbs.

4. When the clips/barbs are free, pull the housing up to


remove from the drive.
5. Disconnect the fan cable.
6. Install the fan in reverse order, noting that:
The fan air flow is up (refer to arrow on fan).

FM

The fan wire harness is toward the front.


The notched housing barb is located in the right-rear corner.
The fan cable connects just forward of the fan at the top of the drive.
Frame Sizes R5 and R6
To replace the internal enclosure fan in frame sizes R5 or R6:
Remove power from drive.
Remove the front cover.
Lift the fan out and disconnect the cable.
Install the fan in reverse order.
Restore power.
Frame Sizes R7/R8 UL type 12 enclosures
The enclosure fan is located in the exhaust box on top of
the UL type 12 enclosure.
1. Remove the left and right filter frames of the exhaust fan
box by lifting them upwards.
PC00021

2. Disconnect the fans electrical connector from the


cabinet roof (top right inside the cabinet).

PC00018

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

35

3. Undo the four fastening screws at the corners of the fan frame. The screws are
through bolts with nuts on the inside of the cabinet. (Do not drop the hardware into
the drive).

PC00014

PC00018

PC00017

4. Remove the fan and fan frame as one unit.

PC00014

5. Disconnect the fan wiring and capacitor from the fan


frame. Then remove the four screws attaching the
fan to the fan frame. Remove the old fan.

PC00020

6. Install the new fan and capacitor


with the replacement part for ABB
in the reverse order of the above.
Ensure the fan is centered on the
velocity stack and rotates freely.

Capacitor
Velocity
Stack
PC00014

Enclosure air filter replacement UL Type 12 enclosures


Frame Sizes R7/R8 UL type 12 enclosure inlet air filter
The inlet air filter for the R7/R8 UL type 12 enclosure is located in the enclosure front
door.
1. While holding the top of the filter frame, pull up on the bottom of the frame. The filter
frame will slide up approximately 3/4 inch and can then safely removed by tilting
away from the cabinet and lifting up.

ACH550-UH

36

ACH550 Installation, Operation and Maintenance Manual

2. Lay the filter frame on a flat work


surface. Remove the 3 retaining
brackets by squeezing the tabbed
corners in towards the middle of
each bracket until the bracket
clears the filter frame. Save these
brackets for replacement. Remove
and inspect the filter.
PC00009

PC00007

3. Install the replacement filter. Be


sure to tuck the filter into the grove
around the entire filter frame. This
is very important for proper
installation.
PC00013

4. Reinstall the 3 filter restraining


brackets. These will prevent the
filter from being pulled out of the
filter frame.
Install the center bracket first.
Install the 2nd bracket
overlapping the center bracket
by 1/2 to the left.

PC00007

PC00009

Install the 3nd bracket


overlapping the center bracket by 1/2 to the right.
1st filter retaining bracket
1st and 2nd filter retaining brackets
All 3 filter retaining brackets

5. Install the filter frame back to the cabinet door. Carefully align the mounting hooks to
the slots in the cabinet door. The hooks should be pointing down. Press in at the
center of the filter frame with your knee and gently press down with your hands at
the top of the frame. The filter frame will slide down approximately
3/4 inch and should be sealed securely to the door around the entire filter frame.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

37

Frame Sizes R7/R8 UL type 12 enclosure exhaust filters


The exhaust filters in the R7/R8 UL type 12 enclosure are located in the exhaust box
at the top of the enclosure.
There are 2 filter frames attached to the exhaust
box.
1. Remove each filter frame:
Lift up on the filter frame until it slides
approximately 3/4 inch.
Pull away from the exhaust box to remove.

PC00021

2. For each filter frame, remove the


wire retainers that hold the filters
in place:
Lay the filter frames on a flat
work surface.
The wire retainers have a
square U shape. Remove by
squeezing the open end of the
PC00001
U towards the middle of the
square until the retainer top (open end of U) clears the filter frame.

PC00019

Save the retainers for reinstallation.


3. Remove and inspect the filter.
4. Install clean filters.
Note: When installing DUSTLOK filter media, the white side
must face to outside of the cabinet, and the orange side
faces in.
Be sure to tuck the filter edges into the groove around the
entire filter frame. This detail is very important for proper
operation.
PC00022

5. Reinstall the filter restrainers.


Insert the base of a retainer
(bottom of U shape) into a
filter frame channel.
Squeeze the open end of the
U until it clears the filter
frame.
Seat the open end of the U
in the filter frame channel.

PC00019

PC00001

Release the retainer to its relaxed, square shape.

ACH550-UH

38

ACH550 Installation, Operation and Maintenance Manual

6. Install each filter frame to the bonnet on top


of the cabinet.
Carefully align the frames mounting
hooks with the slots in the bonnet. (The
hooks should be pointing down.)
Press down at the top of the filter frame.
(The filter frame slides down
approximately 3/4 inch).

PC00012

PC00011

Check all around the filter frame for a


secure seal to the exhaust box.
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their life span
is from 35,00090,000 hours depending on drive loading and ambient temperature.
Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a input power fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements for frame size R5, R6 and R8 are available from ABB. Do not use
other than ABB specified spare parts.
Control panel
Cleaning
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could
scratch the display window.
Battery
A battery is only used in Assistant control panels that have the clock function
available and enabled. The battery keeps the clock operating in memory during
power interruptions.
The expected life for the battery is greater than ten years. To remove the battery, use
a coin to rotate the battery holder on the back of the control panel. Replace the
battery with type CR2032.
Note: The battery is NOT required for any control panel or drive function, except the
clock.

ACH550-UH

ACH550 Installation, Operation and Maintenance Manual

39

ACH550 E-Clipse Bypass

Installation drive
Follow the Installation instructions for the drive on page 3. Failure to observe the
warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.

Installation bypass
WARNING! When the ACH550 with E-Clipse Bypass is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not
make any connections when the ACH550 with E-Clipse Bypass is connected to the
line. Disconnect and lock out power to the drive before servicing the drive. Failure to
disconnect power may cause serious injury or death.

1. Install wiring bypass


WARNING!
Do not connect or disconnect input or output power wiring, or control wires, when
power is applied.
Never connect line voltage to drive output Terminals T1, T2, and T3.
Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of the
unit. Disconnect motor wires before taking any measurements in the motor or
motor wires.
Make sure that power factor correction capacitors are not connected between the
drive and the motor.
Horsepower Range by Voltage Rating

Enclosure
Designation

208/240V

480V

600V

V1/V2

1 to 7.5 HP

1 to 15 HP

2 to 15 HP

V3/V4

10 to 25 HP

20 to 60 HP

20 to 60 HP

B1

1 to 7.5 HP

1 to 15 HP

2 to 15 HP

B2

10 to 25 HP

20 to 60 HP

20 to 60 HP

B3

30 to 100 HP

75 to 200 HP

75 to 150 HP

B4

N/A

250 to 550 HP

N/A

ACH550 E-Clipse Bypass

40

ACH550 Installation, Operation and Maintenance Manual

Connection diagrams Vertical E-Clipse Bypass


ACH550 Vertical E-Clipse Bypass units are configured for wiring access from the
bottom only. The following figure shows the Vertical E-Clipse Bypass wiring
connection points.
ACH550

E-Clipse Bypass
Control Board
Terminals (X2)

Service Switch
(Optional)
Output
Terminals
Output Ground
Lug(s)
Disconnect Switch
or Circuit Breaker

Output
Ground Lug(s)

Input
Ground Lug

Output
Terminals
Service Switch
(Optional)

Input Power
Cable
Terminals
V1/V2

ACH550 E-Clipse Bypass

V3/V4

BP0054

ACH550 Installation, Operation and Maintenance Manual

41

Connection diagrams Standard E-Clipse Bypass (wall mounted)


ACH550 Standard E-Clipse Bypass units are configured for wiring access from the
top. The following figure shows the Standard E-Clipse Bypass (wall mounted) wiring
connection points.

ACH550

User Power
Cable Guides

E-Clipse Bypass
Control Board
Terminals X2

Service Switch
(Optional)

Motor
Terminals
Output Ground
Lug

Disconnect Switch
or Circuit Breaker

Input Power
Terminals
Input Ground
Lug(s)

B1

ACH550 E-Clipse Bypass

42

ACH550 Installation, Operation and Maintenance Manual

User Power Cable Guides


ACH550 Drive
E-Clipse Bypass Control Board
Terminals (X2)
Disconnect Switch
or Circuit Breaker
Input Ground Lug

Input Power Terminals


Motor Terminals
Output Ground Lug
Service Switch (optional)
B2

B2

ACH550 Drive
Output Ground Lug

Input Ground Lug

Motor Terminals

Input Power Terminals

E-Clipse Bypass Control Board


Terminals (X2)

Service Switch (optional)


B3

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

43

Connection diagrams Standard E-Clipse Bypass (R8, floor mounted)


ACH550 Standard E-Clipse Bypass units are configured for wiring access from the
top. The following figure shows the Standard E-Clipse Bypass (floor mounted) wiring
connection points.

ACH550 Drive

Ground Lug Bar

Motor Terminals

Input Power
Terminals

E-Clipse Bypass
Control Board
Terminals ( x2)

Disconnect Switch
or Circuit Breaker

Service Switch
(optional)

ACH550
Control Board
Terminals ( x1)

B4

ACH550 E-Clipse Bypass

44

ACH550 Installation, Operation and Maintenance Manual

Power connections Vertical E-Clipse Bypass configurations


Line input connections
Connect the input power to the terminals
at the bottom of the disconnect switch or
circuit breaker as shown below. Also see
Connection diagrams Vertical E-Clipse
Bypass on page 40. Connect the
equipment grounding conductor to the
ground lug near the input power
connection point.
Motor connections
Connect the motor cables to the terminals
at the bottom of the bypass section as
shown in the figure. Also see Connection
diagrams Vertical E-Clipse Bypass on
page 43. Connect the motor grounding
conductor to the ground lug near the
motor cable terminal block connection
point.

Ground

Input Power
Cables

Motor
Cables

Ground

Power connections Standard E-Clipse Bypass configurations (wall mounted)


Line input connections
Connect input power to the terminals of the disconnect switch or circuit breaker.
Connect the equipment grounding conductor to the ground lug at the top of the
enclosure. The figure below shows the connection points for Standard E-Clipse
Bypass configurations. Also see Connection diagrams Standard E-Clipse Bypass
(wall mounted) on page 41 and Connection diagrams Standard E-Clipse Bypass
(R8, floor mounted) on page 43.
Motor connections
Connect the motor cables to the output terminal block as shown in the figure below.
Also see Connection diagrams Standard E-Clipse Bypass (wall mounted) on page
41 and Connection diagrams Standard E-Clipse Bypass (R8, floor mounted) on
page 43. The motor grounding conductor can be connected to the ground lug near
the terminal block.
Note: Route cables through the cable guides on the left side of the enclosure. Use
separate conduits for input power and motor cables. Follow the guides to separate
the cables from each other.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

User Power
Cable Guides

45

Ground

Motor
Cables

Motor
Cables

Ground
Input Power
Cables

Input
Power
Cables

Standard Configuration (B1/B2)

Standard Configuration (B3)

Motor Cables

Input Power
Cables

Ground

Ground
UL Type 3R Configuration (B1/B2)

Note: Type 3R enclosures are designed to be mounted on a wall. For 3R enclosure


back plates which maintain 3R integrity when the enclosure is mounted on an open
rack system, contact your ABB HVAC Drives Distributor.

ACH550 E-Clipse Bypass

46

ACH550 Installation, Operation and Maintenance Manual

WARNING! Check the motor and motor wiring insulation before connecting the
ACH550 to line power. Follow the procedure on page 12. Before proceeding with the
insulation resistance measurements, check that the ACH550 is disconnected from
incoming line power. Failure to disconnect line power could result in death or serious
injury.
Install the control wiring
Connect control wiring to terminal block X1 on the ACH550 control board and to
terminal block X2 on the E-Clipse Bypass control board. For more information on
these connections, refer to the following:
X1 terminal block location and terminal data are defined in the ACH550-UH
Users Manual.
X2 terminal block location is illustrated in the figures starting with Connection
diagrams Vertical E-Clipse Bypass on page 40.
X2 terminal data are provided in Basic control connections for E-Clipse HVAC
Default on page 52.
Basic connections are described in the following paragraphs. Alternate
configurations using the E-Clipse Bypass macro are described in the ACH550
Users Manual.
On Terminal Block X1 inside the ACH550, analog inputs and outputs and
additional digital input and relay output connections (AI1, AI2, AO1, AO2,
DI1DI6 and RO1RO6) are available for use.
Note: The E-Clipse Bypass control circuitry uses serial communications connections
(X1:28X1:32) inside the ACH550. These connections are not available for any
other purpose and must not be reconfigured.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

47

Basic connections
The figure on page 52 shows the basic
control connections for use with the EClipse Bypass HVAC Default macro.
These connections are described in the
following paragraphs.
In typical installations, only analog input
wires connect to the ACH550 terminal
block, with other control connections
made on the E-Clipse Bypass control
board.

Digital I/O
control
terminals

EIA-485
port
control
terminals

Use wire ties to permanently affix control/


communications wiring to the hooked wire
race tie points provided, maintaining a
minimum 6 mm (1/4") spacing from power
wiring.

Drives power connection terminals


The following tables list power and motor cable terminal sizes for connections to an
input circuit breaker or disconnect switch, a motor terminal block and ground lugs.
The tables also list torque that should be applied when tightening the terminals.

ACH550 E-Clipse Bypass

48

ACH550 Installation, Operation and Maintenance Manual

Vertical enclosure terminals


HP

Identification

Frame
Size

Maximum Wire Size Capacities of Power Terminals


Circuit
Breaker

Disconnect
Switch

Motor
Termination

Ground
Lugs

#6
30 in-lbs

#4
35 in-lbs

208240 Volt
1

ACH550-VxR-04A6-2

R1

1.5

ACH550-VxR-06A6-2

R1

ACH550-VxR-07A5-2

R1

ACH550-VxR-012A-2

R1

ACH550-VxR-017A-2

R1

7.5

ACH550-VxR-024A-2

R2

10

ACH550-VxR-031A-2

R2

15

ACH550-VxR-046A-2

R3

20

ACH550-VxR-059A-2

R3

25

ACH550-VxR-075A-2

R4

#10
35 in-lbs

#8
40 in-lbs

#2
50 in-lbs

#1
50 in-lbs

#10
7 in-lbs

#8
7 in-lbs

#4
18 in-lbs
#1
55 in-lbs

#2
50 in-lbs

#2/0
120 in-lbs

#2
50 in-lbs

380480 Volt
1/1.5

ACH550-VxR-03A3-4

R1

ACH550-VxR-04A1-4

R1

ACH550-VxR-06A9-4

R1

ACH550-VxR-08A8-4

R1

7.5

ACH550-VxR-012A-4

R1

10

ACH550-VxR-015A-4

R2

15

ACH550-VxR-023A-4

R2

20

ACH550-VxR-031A-4

R3

25

ACH550-VxR-038A-4

R3

30

ACH550-VxR-045A-4

R3

40

ACH550-VxR-059A-4

R4

50

ACH550-VxR-072A-4

R4

60

ACH550-VxR-078A-4

R4

ACH550 E-Clipse Bypass

#10
35 in-lbs

#8
40 in-lbs
#3
50 in-lbs

#1
50 in-lbs

#10
7 in-lbs

#6
30 in-lbs

#4
35 in-lbs

#8
7 in-lbs

#4
18 in-lbs
#1
55 in-lbs
#1
70 in-lbs

#2
50 in-lbs
#2
50 in-lbs
#2/0
120 in-lbs

ACH550 Installation, Operation and Maintenance Manual

HP

Identification

Frame
Size

49

Maximum Wire Size Capacities of Power Terminals


Circuit
Breaker

Disconnect
Switch

Motor
Termination

Ground
Lugs

#6
30 in-lbs

#4
35 in-lbs

500600 Volt
2

ACH550-VxR-02A7-6

R2

ACH550-VxR-03A9-6

R2

ACH550-VxR-06A1-6

R2

7.5

ACH550-VxR-09A0-6

R2

10

ACH550-VxR-011A-6

R2

15

ACH550-VxR-017A-6

R2

20

ACH550-VxR-022A-6

R3

25

ACH550-VxR-027A-6

R3

30

ACH550-VxR-032A-6

R4

40

ACH550-VxR-041A-6

R4

50

ACH550-VxR-052A-6

R4

60

ACH550-VxR-062A-6

R4

#8
62 in-lbs

#8
7 in-lbs

#4
62 in-lbs

#2
50 in-lbs
#4
18 in-lbs

#1
62 in-lbs

#1
55 in-lbs

#2/0
120 in-lbs

#2
50 in-lbs

#1
70 in-lbs

Standard enclosure terminals


HP

Identification

Frame
Size

Maximum Wire Size Capacities of Power Terminals


Circuit
Breaker

Disconnect
Switch

Motor
Termination

Ground
Lugs

#6
30 in-lbs

#4
35 in-lbs

208240 Volt
1

ACH550-BxR-04A6-2

R1

1.5

ACH550-BxR-06A6-2

R1

ACH550-BxR-07A5-2

R1

ACH550-BxR-012A-2

R1

ACH550-BxR-017A-2

R1

7.5

ACH550-BxR-024A-2

R2

10

ACH550-BxR-031A-2

R2/R3

15

ACH550-BxR-046A-2

R3

20

ACH550-BxR-059A-2

R3

25

ACH550-BxR-075A-2

R4

#8
40 in-lbs

#8
7 in-lbs

#2
50 in-lbs
#1
50 in-lbs

#4
18 in-lbs

#2
120 in-lbs

#2
50 in-lbs

#1
55 in-lbs

ACH550 E-Clipse Bypass

50

ACH550 Installation, Operation and Maintenance Manual

HP

Identification

Frame
Size

Maximum Wire Size Capacities of Power Terminals


Circuit
Breaker

Disconnect
Switch

Motor
Termination

Ground
Lugs

208240 Volt, continued


30

ACH550-BxR-088A-2

R4

40

ACH550-BxR-114A-2

R4

50

ACH550-BxR-143A-2

R6

60

ACH550-BxR-178A-2

R6

75

ACH550-BxR-221A-2

R6

100

ACH550-BxR-248A-2

R6

#1/0
70 in-lbs
350 MCM
274 in-lbs

2 x 250 MCM
274 in-lbs

300 MCM
275 in-lbs

2 x 250 MCM
274 in-lbs

#1
53 in-lbs
250 MCM
300 in-lbs
400 MCM
375 in-lbs

3 x #3/0
250 in-lbs

2 x 500 MCM
375 in-lbs

380480 Volt
1/1.5

ACH550-BxR-03A3-4

R1

ACH550-BxR-04A1-4

R1

ACH550-BxR-06A9-4

R1

ACH550-BxR-08A8-4

R1

7.5

ACH550-BxR-012A-4

R1

10

ACH550-BxR-015A-4

R2

15

ACH550-BxR-023A-4

R2

20

ACH550-BxR-031A-4

R3

25

ACH550-BxR-038A-4

R3

30

ACH550-BxR-045A-4

R3

40

ACH550-BxR-059A-4

R4

50

ACH550-BxR-072A-4

R4

#1
55 in-lbs

60

ACH550-BxR-078A-4

R4

#1
70 in-lbs

75

ACH550-BxR-097A-4

R4

#1/0
70 in-lbs

100

ACH550-BxR-125A-4

R5

125

ACH550-BxR-157A-4

R6

150

ACH550-BxR-180A-4

R6

200

ACH550-BxR-246A-4

R6

250

ACH550-BxR-316A-4

R8

300

ACH550-BxR-368A-4

R8

350

ACH550-BxR-414A-4

R8

400

ACH550-BxR-486A-4

R8

ACH550 E-Clipse Bypass

#8
40 in-lbs

#1
50 in-lbs

350 MCM
274 in-lbs

#8
7 in-lbs

#4
18 in-lbs

300 MCM
275 in-lbs

#6
30 in-lbs

#4
35 in-lbs

#2
50 in-lbs
#2
50 in-lbs
#2/0
120 in-lbs

#1
53 in-lbs
250 MCM
300 in-lbs
400 MCM
375 in-lbs

2 x 250 MCM
274 in-lbs

2 x 250 MCM
274 in-lbs

2 x 500 MCM
375 in-lbs

2 x 500 MCM
274 in-lbs

2 x 500 MCM
275 in-lbs

2 x 600 MCM
500 in-lbs

3 x #3/0
250 in-lbs

5 Bus bar
holes
(13/32"
bolts)

ACH550 Installation, Operation and Maintenance Manual

HP

Identification

Frame
Size

51

Maximum Wire Size Capacities of Power Terminals


Circuit
Breaker

Disconnect
Switch

Motor
Termination

Ground
Lugs

#6
30 in-lbs

#4
35 in-lbs

500600 Volt
2

ACH550-BxR-02A7-6

R2

ACH550-BxR-03A9-6

R2

ACH550-BxR-06A1-6

R2

7.5

ACH550-BxR-09A0-6

R2

10

ACH550-BxR-011A-6

R2

15

ACH550-BxR-017A-6

R2

20

ACH550-BxR-022A-6

R3

25

ACH550-BxR-027A-6

R3

30

ACH550-BxR-032A-6

R4

#8
62 in-lbs

#8
7 in-lbs

#2
50 in-lbs

#1
62 in-lbs

#4
18 in-lbs

40

ACH550-BxR-041A-6

R4

50

ACH550-BxR-052A-6

R4

#1
55 in-lbs

60

ACH550-BxR-062A-6

R4

#1
75 in-lbs

75

ACH550-BxR-077A-6

R6

100

ACH550-BxR-099A-6

R6

125

ACH550-BxR-125A-6

R6

150

ACH550-Bx-R144A-6

R6

300 MCM
274 in-lbs

#2
120 in-lbs

#1/0
70 in-lbs

#1
53 in-lbs

300 MCM
275 in-lbs

250 MCM
300 in-lbs

#2
50 in-lbs

3 x #3/0
250 in-lbs

ACH550 E-Clipse Bypass

52

ACH550 Installation, Operation and Maintenance Manual

Basic control connections for E-Clipse HVAC Default

Parameters Changed Relative to E-Clipse HVAC Default


Parameter Number

Description

Setting

Smoke Control (Override1) is a fixed input. Closing Digital Input 6 will place the E-Clipse Bypass in
Smoke Control mode which may reassign the function of the other Digital Inputs. Refer to the
Smoke Control (Override1) documentation.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

53

2. Check installation bypass


Control panel settings and checks
Apply power to the E-Clipse Bypass unit. The ACH550 Control Panel should show
the operating status of the drive. If the E-Clipse Bypass Control Panel displays a
PHASE SEQ (Phase Sequence) fault, remove power, wait at least 5 minutes and
then swap any two input phase wires. If the motor is a standard 208 V, 60 Hz motor
connected to a 208 V drive or a 460 V, 60 Hz motor connected to a 480 V drive, the
default parameter settings should be suitable for the initial tests described below. If
the motors rating is not 208 V or 460 V, 60 Hz, the MOTOR NOM VOLT and
MOTOR NOM FREQ parameters will need to be properly set before proceeding.
Refer to the ACH550-UH Users Manual and set the parameters as required.
Note: The settings for ALL external serial communication between the ACH550 with
E-Clipse Bypass and any Building Automation System are configured using the
E-Clipse Bypass operator panel. DO NOT attempt to configure the external serial
communication connection using the ACH550 operator panel!
The settings for internal communication between the ACH550 and the E-Clipse
Bypass are configured at the factory and require no adjustment.
Drive Link recovery procedure
If the ACH550 Drive communication settings are unintentionally changed during
setup a Drive Link Fault, Drive Link Error or Drive Setup alarm may be
displayed. Should this occur, accomplish the following steps in order.
Using the ACH550 Drive Keypad
1. Set Parameter 9802 to STD MODBUS
2. Set Parameter 9902 to E-CLIPSE
3. Cycle Power
Following the above steps, in order, should restore proper communications between
the ACH550 Drive and the E-Clipse Bypass. Should the E-Clipse Keypad continue to
display a Drive Link Fault, Drive Link Error or Drive Setup alarm, check the
following parameter settings to ensure they have been recovered. If necessary,
individually set the correct parameter settings as indicated below and cycle power.
The only ACH550 Drive macro that provides the proper configuration settings by
default is the E-Clipse Bypass macro. If any other ACH550 Drive macro is used, that
macro should be selected after completing the initial tests. When using any other
macro the following ACH550 Drive parameter values must be set and power cycled
or the E-Clipse Bypass will not function properly:
Parameter 9802 must be set to STD MODBUS
Parameter 1001 must be set to Comm
Parameter 1002 must be set to Comm
Parameter 1601 must be set to Comm

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Parameter 1608 must be set to Comm


Parameter 5303 must be set to 76.8 kb/s
Parameter 5304 must be set to 8 EVEN 1
Parameter 5305 must be set to DCU PROFILE
Parameter 5310 must be set to 103
Parameter 5311 must be set to 104
Power must be cycled
Refer to the ACH550-UH Users Manual for additional information.
Note: Run motor from drive before attempting bypass operation.
System check: motor connected to ACH550 with E-Clipse Bypass
After performing the control panel checks and setting the ACH550 Drive Start-up
Data parameters, check the operation of the ACH550 Drive with E-Clipse Bypass
with the motor connected as follows:
1. Disconnect and lock out power to the E-Clipse Bypass unit, wait at least five minutes
before disconnecting power.
2. Connect the motor to the output terminals.
CAUTION: If the Bypass Override (Override 2) input contact is closed, the motor will
start across the line as soon as power is applied.
If the Safety Interlock and Run Enable input contacts are closed and the Smoke
Control (Override 1) input contact is closed, the motor will start across the line as
soon as power is applied.
If the Start/Stop, Safety Interlock and Run Enable input contacts are closed and the
system is in the Bypass mode and in either Hand or Auto, the motor will start across
the line as soon as power is applied.
If the Start/Stop, Safety Interlock and Run Enable input contacts are closed and the
system is in the Drive mode with the drive in either Hand or Auto mode, the motor
will start on the drive as soon as power is applied.
In order to prevent the motor from starting, the system should be in the Drive mode
and the drive should be OFF when the power is disconnected at the end of the
previous series of control panel settings and checks.
In order to prevent the motor from running without disconnecting the motor, open the
Run Enable and Safety Interlock contacts on bypass control board terminals X2:2,
X2:3 and X2:4 before applying power. Set the bypass to Drive mode and the drive to
OFF.

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3. Apply power to the E-Clipse Bypass unit. The ACH550 Control Panel display should
be illuminated. On the bypass control panel, both the display and Enabled LED
should be illuminated. If the Enabled LED is not illuminated solid green, check to see
that closed contacts or jumpers connect terminal X2:3 to X2:4 and X2:2 to X2:7 on
the bypass control board.
4. The Drive Selected LED should be illuminated. If not, press the Drive Select key to
switch to Drive mode. Leave the system in the Drive mode when proceeding to the
next step.
5. Press the Hand key on the ACH550 Control Panel. Press and hold the UP key until
the motor just starts rotating.
Note: If the ACH550 Control Panel displays an OVERCURRENT or EARTH FAULT,
disconnect and lock out power to the E-Clipse Bypass unit. Wait at least 5 minutes.
Disconnect the motor leads from the E-Clipse Bypass unit and Megger each motor
lead to ground to determine if the motor is good. Check the power leads from the
Drive / Bypass to the motor for damaged or improper wiring. If the ACH550 Control
Panel displays any other drive faults, correct the fault condition before proceeding to
the next step.

CAUTION: Check motor rotation direction as soon as the motor begins to move. If
motor does not rotate in the correct direction, shut down the drive, disconnect and
lock out power to the drive and wait five minutes. Swap any two motor output wires
(T1, T2, and T3). Incorrect motor rotation direction may cause equipment damage.
6. Increase the speed to 60 Hz or the highest safe operating speed.
7. Press the OFF key on the drive control panel. The motor should stop.
If the drive does not operate according to these steps, refer to the ACH550-UH
Users Manual.
If the drive operates according to these steps, your ACH550 with E-Clipse Bypass is
ready to use with preset or modified macro settings.
Note: The settings for ALL external serial communication between the ACH550 with
E-Clipse Bypass and any Building Automation System are configured using the
E-Clipse Bypass operator panel. DO NOT attempt to configure the external serial
communication connection using the ACH550 operator panel!
The settings for internal communication between the ACH550 and the E-Clipse
Bypass are configured at the factory and require no adjustment.

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Note: Both the ACH550 Drive and the E-Clipse Bypass include preset application
macros. The only ACH550 Drive macro that provides the proper configuration
settings by default is the E-Clipse HVAC Default macro (9902 = 15). If any other
ACH550 drive macro or any modified setting of the E-Clipse HVAC Default macro is
used the following ACH550 Drive parameter values must be set and power cycled or
the E-Clipse Bypass will not function properly:
Parameter 9802 must be set to STD MODBUS
Parameter 1001 must be set to Comm
Parameter 1002 must be set to Comm
Parameter 1601 must be set to Comm
Parameter 1608 must be set to Comm
Parameter 5303 must be set to 76.8 kb/s
Parameter 5304 must be set to 8 EVEN 1
Parameter 5305 must be set to DCU PROFILE
Parameter 5310 must be set to 103
Parameter 5311 must be set to 104
Power must be cycled
Refer to the ACH550-UH Users Manual for programming instructions.
Note: Run motor from drive before attempting bypass operation.
System check: motor disconnected from the ACH550 with E-Clipse Bypass
If you are familiar with the E-Clipse Bypass operation, you may skip the following
section. Otherwise, after performing the system checks and setting the ACH550
Drive Start-up Data parameters, become familiar with the operation of the ACH550
Drive with E-Clipse Bypass without the motor connected as follows:
1. Disconnect and lock out power to the E-Clipse Bypass unit, wait at least five minutes
after disconnecting power.
2. Disconnect the motor from the E-Clipse Bypass unit.
3. Apply power to the E-Clipse Bypass unit by turning on the branch circuit disconnect
device and the bypass disconnect switch or circuit breaker.
4. The ACH550 Control Panel display should be illuminated. On the E-Clipse Bypass
control panel, both the display and Enabled LED should be illuminated. If the
Enabled LED is not illuminated solid green, check to see that closed contacts or
jumpers connect terminal X2:3 to X2:4 and X2:2 to X2:7 on the bypass control
board.

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5. On the E-Clipse Bypass control panel, either the Drive Selected or Bypass Selected
LED should be illuminated. Pressing the Drive Select or Bypass Select key should
switch the bypass back and forth between the Drive mode and the Bypass mode as
indicated by the LEDs above each button. Check that the bypass control panel
switches the system between modes. Leave the system in the Bypass mode when
proceeding to the next step.
6. Check to see that pressing the:
Auto key on the bypass control panel causes the bottom line on the E-Clipse
Bypass display to indicate Bypass in Auto
Hand key on the bypass control panel generates a Motor Phase Fault.
Under normal conditions (motor connected) pressing the Hand key on the bypass
control panel causes the bottom line on the E-Clipse Bypass display to indicate
Hand #A Run
OFF key on the bypass control panel causes the bottom line on the E-Clipse
Bypass display to indicate Off Stop
7. For Steps 8 through 14, ACH550 Drive Parameter 9904 must be set to Scalar:
Freq. After successful completion of Step 13, Parameter 9904 may be set to
Vector: Speed if very specific application requirements make it necessary to use
this type of motor control. Operation using the Vector: Speed setting is
unnecessary for control of almost all fan and pump applications. Refer to the
ACH550-UH Users Manual for details on setting parameters.
8. Press the Drive Select key on the E-Clipse Bypass control panel. The Drive Select
LED should be illuminated.
9. Check to see that pressing the:
Auto key on the bypass control panel causes the E-Clipse Bypass display to
indicate Bypass in Auto
Hand key on the bypass control panel causes no change to the E-Clipse Bypass
display
OFF key on the bypass control panel causes the E-Clipse Bypass display to
indicate Bypass in Off
10. Press the HAND key on the drive control panel. Note that the top line of the control
panel display indicates HAND and run as a clockwise rotating arrow. The Drive
Run LED on the E-Clipse Bypass control panel should be illuminated.
11. Press the UP arrow on the drive control panel. Note that the speed reference
indication in the top line of the drive control panel display increases from 0.0% SP.
12. In the middle line of the drive control panel display, the output current indication
should indicate 0.0 A.
13. Press the DOWN arrow on the drive control panel until the speed and frequency
indications return to 0.0.
14. Press the OFF key on the drive control panel. Note that the bottom line of the drive
contol panel display indicates Off.

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If the ACH550 Drive and E-Clipse Bypass operate according to these steps, and you
have familiarized yourself with their operation, disconnect and lock out power to
prepare for the next test.
WARNING! Wait at least five minutes after disconnecting power from the drive
before you attempt to service the drive. Bus capacitors in the intermediate DC circuit
must discharge before servicing the drive. Using a meter rated for 1000 VDC, check
for zero volts at:
Terminals BRK+ to GND and BRK- to GND (frame size R1/R2)
Terminals UC+ and UC- (frame size R3R8).
If the drive does not operate according to these steps, refer to the ACH550-UH
Users Manual.
3. Check jumpers and switches
The settings described in this section are factory set and, for most situations, do not
require adjustment. However, it is a good practice to review these settings to confirm
that they are appropriate for the configuration installed.
Jumper and switch locations
The figure below shows the locations of the SW1 DIP switch on the E-Clipse Bypass
control board. The function and setting of this switch is explained in the following
paragraph.

Factory
installed
jumpers

Hooked wire
race tie points

ACH550 E-Clipse Bypass

Serial Communications
Termination Resistors
SW1
ON=Terminated
OFF=Not Terminated

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59

DIP switch settings


The DIP switch is used to configure the serial communications termination resistors.
To reduce noise on the serial communications network, terminate the EIA-485
network using 120 ohm resistors at both ends of the network. Use the DIP switches
to connect or disconnect the on-board termination resistors. Both switches must be
positioned in the ON or OFF position to correctly configure the termination resistors.
Note: When using embedded protocols, set SW1 in the OFF position.
Circuit breaker settings
On some ACH550 E-Clipse Bypasses, the circuit breaker has adjustable settings for
instantaneous current protection. The factory default settings are practical for most
applications. Refer to the ABB SACE Instruction Sheet (supplied with these units)
for additional information on the adjustment of these settings.

Operation
E-Clipse bypass configurations
The ACH550 with E-Clipse Bypass is an ACH550 AC adjustable frequency drive in
an integrated UL type 1, UL type 12 or UL type 3R package with a bypass motor
starter. The ACH550 with E-Clipse Bypass provides:
Disconnect switch or circuit breaker with door mounted control lever. The lever
can be padlocked in the OFF position (padlock not supplied).
Bypass starter.
Motor overload protection.
Local operator panel with indicating lights and multifunction display.
Provisions for external control connections.
Embedded communications for major BMS protocols including BACnet, Johnson
Controls International N2, Siemens Building Technologies FLN, and Modbus
Optional fieldbus adapters for connection to additional BMS protocols including
LonWorks and Ethernet
Optional drive service switch (drive input disconnect), the functional equivalent of
a three-contactor bypass arrangement.

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The following shows the front view of the ACH550 E-Clipse Bypass vertical
configuration, and identifies the major components.
ACH550 Drive

ACH-CP-B
Control Panel

E-Clipse Bypass Control Panel

Operating Handle
for Disconnect Switch
or Circuit Breaker
BP0091

E-Clipse Bypass

The following shows the front view of the ACH550 E-Clipse Bypass standard
configurations, and identifies the major components.
ACH550 Drive with E-Clipse Bypass
ACH-CP-B
Control Panel

E-Clipse Bypass
Control Panel

Operating Handle
for Disconnect Switch
or Circuit Breaker

E-Clipse Bypass
(R8)

ACH550 E-Clipse Bypass

BP0092

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61

The following is a typical power diagram.


Drive with E-Clipse Bypass
Bypass
Control

Disconnect Switch
or Circuit Breaker
3 Phase
Input Power

ACH550
Drive

Service Switch
(Optional)

Drive Input Fuse

Drive Output
Contactor

Motor

3
Bypass
Contactor

Bypass control
The bypass control panel features:
Ready Indication
(Display Illuminated)

LCD Display
Down
Escape

Up
Enter

Enabled LED
Drive and Bypass
Selected/Faulted LEDs

ON/Hand Key

OFF/Reset Key

Drive/Bypass Select Keys

Auto Key

Motor Run LED

Ready (Power On) Indication


The Ready (Power On) indication is provided by the bypass control panel. The
bypass control panel display will be illuminated and text will be displayed when the
disconnect switch or circuit breaker is closed and control power is applied to the
bypass.
Enabled LED
The Enabled LED is illuminated green under the following conditions:
Both the Safety Interlock(s) and Run Enable contacts are closed.
The Safety Interlock contact(s) are closed with no Start command present.
The Enabled LED flashes green if the Run Enable contact is open and when the
Safety Interlock contact(s) are closed and a Start command is present.
The Enabled LED is illuminated red when the Safety Interlock contact(s) are open.

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Motor Run LED


The Motor Run LED is illuminated green when the motor is running in either bypass
mode or in drive mode. The Motor Run LED flashes green to indicate the system has
been placed in an Override condition.
Bypass Faulted LED
The Bypass Faulted LED is illuminated or flashes red when the motor or bypass
protection functions have shut down the bypass. The specific nature of the fault is
indicated on the bypass control display. Refer to the Diagnostics section of this
manual for more details.
Drive Selected LED
The Drive Selected LED is illuminated green when the drive has been selected as
the power source for the motor and no drive fault is present.
Bypass Selected LED
The Bypass Selected LED is illuminated or flashes green when the bypass has been
selected as the power source for the motor and no bypass fault is present.
Drive Faulted LED
The Drive Faulted LED is illuminated red when the bypass has lost its
communications link with the drive or when the motor or drive protection functions
have shut down the drive. The specific nature of the fault is indicated on the drive
control panel display. Refer to the Diagnostics section on page 65 of the
ACH550-UH Users Manual for more details.
Automatic Transfer
The Automatic Transfer indication is provided on the bypass control panel. The
bypass control display will continuously flash an alarm to indicate the system has
automatically transferred to Bypass after a Drive fault. The Bypass Selected LED
flashes green when the system has automatically transferred to bypass operation.
The bypass event log will also record this event.
Auto Indication
The Auto Indication is provided on the bypass control panel default display when the
bypass control panel Auto key is pressed. Normally this indicates that the Auto Start
contact or serial communications has been selected as the means for starting and
stopping the motor in the bypass mode.
Off Indication
The Off Indication is provided on the bypass control panel default display when
bypass control panel Off key is pressed.
Hand Indication
The Hand Indication is provided on the bypass control panel default display when
the motor has been started manually in the bypass mode.
Drive Select Key
The Drive Select Key selects the drive as the power source for the motor.

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63

Bypass Select Key


The Bypass Select Key selects the bypass as the power source for the motor.
Off/Reset Key
The Off/Reset Key may be used to manually stop the motor if the motor has been
running on bypass power. The Off/Reset key also resets most bypass faults. It may
take several minutes before the bypass can be reset after an overload trip. If a
bypass fault condition is present the second press of this key places the bypass in
the OFF mode.
Auto Key
The Auto Key selects the Auto Start contact or serial communications as the means
for starting and stopping the motor in the bypass mode.
Hand Key
The Hand Key can be used to manually start the motor when the bypass has been
selected as the power source for the motor.
Bypass control panel modes
The HVAC Bypass Control Panel has several different modes for configuring,
operating and diagnosing the bypass. Select MENU and use the UP/DOWN buttons
to select modes. The modes are:
Default Display mode Provides (HAND/OFF/AUTO) indication of the bypass
operating control mode.
Bypass Status mode Provides status indications of the current system operating
conditions.
Start-Up Parameter Mode Provides a list of parameters or operating conditions
that may be configured or viewed during startup.
Parameter List mode Used to edit parameter values individually.
Changed Parameter mode Displays changed parameters.
Bypass Fault Display mode If there is an active bypass fault, the control panel
will flash the fault number and fault diagnostic indication in English.
Bypass Alarm Display mode If there is an active bypass alarm, the control panel
will flash the alarm number and alarm diagnostic indication in English.
Start-up by changing the parameters from the start-up list
To change the parameters, follow these steps:
1

The Default Display indicates the


Bypass Control mode.

Press ENTER to enter the Main Menu.


ENTER

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Select the Startup Params with the


Up/Down arrows and press ENTER.

Select the appropriate Parameter with


the Up/Down arrows and press
ENTER.

Press the Up/Down arrows to change


the Parameter Value.

Press ENTER to store the modified


value or press ESC to leave the
Parameter Edit mode.

ENTER

ENTER

ENTER

Press ESC to return to the Main Menu,


and again to return to the. Default
Display.

ESC

or

*1601 START/STOP
1613 BP DISABLE

*1601 START/STOP
1613 BP DISABLE

ESC

Start-up by changing the parameters individually from the parameter list


To change the parameters, follow these steps:
1

The Default Display indicates the


Bypass Control mode.

Press ENTER to enter the Main Menu.

Select the Parameter List with the Up/


Down arrows and press ENTER.

ENTER

Select the appropriate Parameter


Group with the Up/Down arrows and
press ENTER.

ENTER

Select the appropriate Parameter in a


group with the Up/Down arrows and
press ENTER.

Press the Up/Down arrows to change


the Parameter Value.

Press ENTER to store the modified


value or press ESC to leave the
Parameter Edit mode.

ENTER

Press ESC to return to the listing of


Parameter Groups, and again to
return to the Main Menu.

ACH550 E-Clipse Bypass

ENTER

ENTER

ESC

or

ESC

ESC

ACH550 Installation, Operation and Maintenance Manual

Press ESC to return to the Default


Display from the Main Menu.

65

ESC

Note: In the Parameter Edit mode the current parameter value appears below the
parameter name.
Note: To view the default parameter value, press the Up/Down arrows
simultaneously. Press Enter to restore the default parameter value or press ESC to
leave the Parameter Edit mode.

Diagnostics
Fault listing
Fault
Code

Fault Name In
Panel

Fault

Possible Cause

Corrective Action

3001

COIL CURR FBK

RBCU is sensing
abnormal current
feedback when neither
contactor should be
energized

Defective component
on RBCU

Change RBCU

3002

BYP CNTACT
STUCK

M2 contactor indicates
it is not prepared to
move on a power up
check of the contactor
or after contact is
commanded to open

Defective Contactor
Defective RBCU

Disconnect incoming
power from unit
Check if contactor
armature moves
freely. If armature
moves freely, then
change the RBCU. If
armature does not
move freely, then
change individual
contactor (M2) or the
complete assembly
(RCSA-0x)

3003

DRV CNTACT
STUCK

M1 contactor indicates
it is not prepared to
move on a power up
check of the contactor
or after contact is
commanded to open

Defective Contactor
Defective RBCU

Disconnect incoming
power from unit
Check if contactor
armature moves
freely. If armature
moves freely, then
change the RBCU. If
armature does not
move freely, then
change individual
contactor (M1) or the
complete assembly
(RCSA-0x)

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Fault
Code

Fault Name In
Panel

Fault

Possible Cause

Corrective Action

3004

BYPASS COIL
OPEN

M2 contactor will not


close when
commanded to do so

Loose J8 connector
on RBCU
Loose wires on
contactor terminals A1
and/or A2
Bad Output on RBCU
Bad Contactor

Verify that J8
connector is firmly
seated.
With incoming power
disconnected, check
for tightness of A1 and
A2 terminals
Swap RBCU
Change Contactor/
Assembly

3005

DRIVE COIL
OPEN

M1 contactor will not


close when
commanded to do so

Loose J8 connector
on RBCU
Loose wires on
contactor terminals A1
and/or A2
Bad Output on RBCU
Bad Contactor

Verify that J8
connector is firmly
seated.
With incoming power
disconnected, check
for tightness of A1 and
A2 terminals
Swap RBCU
Change Contactor/
Assembly

3006

UNDERVOLTAGE

Message only occurs


if drive is controlling
the motor and the
power to the bypass is
removed before the
drive phases back.
Message will appear
in the fault log. This
message will only
appear when drive
contactor opens when
drive is operating

Loose J7 connector
on RBCU unit
Loose input wiring
Incoming power
problems

Check that J7
connector is firmly
seated in RBCU
Check tightness of
incoming connections
Check Parameter
0413 to view voltage
level at time of trip
Check upstream
protection

3008

DRIVE AI2 LOSS

Only displayed when


in Supervisory mode.
Indicates that AI2 on
the drive has failed.

Check ACH550
manual for AI2 loss

Check ACH550
manual for AI2 loss

3009

MTR OVERLOAD

Bypass opens on
motor overload
conditions defined in
the drive

Drive Mode:
Bad Motor
Bad CTs
Bad RBCU
Bypass mode:
Bad motor
Bad CTs
Bad RBCU
Either mode:
low input voltage

Check if overload
condition exists
Drive Mode:
Refer to 550 manual
for proper
troubleshooting
techniques
Bypass Mode:
Check that J2
connector is firmly
seated in RBCU
Use clamp meter to
verify mtr current vs.
display in parameter
0101
Check input voltage

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

Fault
Code

Fault Name In
Panel

Fault

67

Possible Cause

Corrective Action

3010

INP PHASE A
LOSS

Fault will be generated


only when trying to
close the bypass
contactor and the
RBCU does not sense
voltage on Phase A

Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J7 connector
Check yellow wire on
input block
Check incoming
voltage, phase to
ground

3011

INP PHASE B
LOSS

Fault will be generated


only when trying to
close the bypass
contactor and the
RBCU does not sense
voltage on Phase B

Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J7 connector
Check black wire on
input block
Check incoming
voltage, phase to
ground

3012

INP PHASE C
LOSS

Fault will be generated


only when trying to
close the bypass
contactor and the
RBCU does not
senses voltage on
Phase C

Loose J7 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J7 connector
Check red on input
block
Check incoming
voltage, phase to
ground

3013

DRIVE 1ST
START

Fault generated if
attempting to close the
bypass contactor with
out running the
bypass in drive mode
first.

NA

Run bypass unit in


drive mode before
attempting bypass
mode

3014

COIL POW
SUPPLY

Coil power supply has


failed to reach rated
voltage

Internal failure on
RBCU unit
Shorted contactor coil

Cycle power on
bypass unit. If
contactor coil is
shorted, fault 3023 or
3024 will be
generated.
If 3023 or 3024 is
generated, replace
respective contactor
If 3023 or 3024 is not
generated on power
up, replace RBCU
unit.

3016

EARTH FAULT

Declared if attempting
to close the bypass
contactor when the
drive has earth fault
declared

Earth fault in motor

Refer to the fault code


16 on page 25.

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Fault
Code

Fault Name In
Panel

Fault

Possible Cause

Corrective Action

3017

MTR
UNDERLOAD

If motor power(%)
level falls below
minimum power level
establish in parameter
3003 for the time (s)
set in parameter 3002
fault will be generated.
Parameter 3003 is a
percentage of motor
power as defined in
the drive via
parameter 9909. Fault
only applies to bypass
mode

Broken belt

Check load
Reset bypass keypad
Check fault code 17
on page 25, for further
action

3018

MAX CYCLE
FAULT

Supervisory Mode
only. Declared if
bypass contactor is
closed by supervisory
control 16 times within
a 1 hour period.

High and low levels of


hysteresis band are
too tight

Check parameters
3202-3205. Increase
time delays on
parameters 3204 and
3205

3019

DRIVE LINK
FAULT

Supervisory Mode
Only. Fault generated
if RS-485 link between
drive and bypass
stops communicating.

Bad cable/connection
between drive and
bypass.
Communication
improperly set in drive
Parameter 9802.
Application Macro
improperly set in drive
parameter 9902.

Proper seating of
cable in drive and
RBCU(connector J3)
Check drive
parameter 9802
(Modbus) and 9902
(E-Clipse)
Check drive Group 53
Follow DriveLink
recovery procedure

3020

PHASE SEQ

Sequence of 3 phase
voltage input is such
that bypass operation
will result in motor
rotation opposite of
drive forward
operation.

Phase sequence
unknown at time of
wiring

Swap any two of the


three input wires to the
bypass unit

3021

PH A CURR FBK

Fault is generated
when current in Phase
A is detected and the
bypass contactor is
open

Loose CT connection
Bad RBCU
Bad CT

Check J2 connector
for proper seating
Check connector on
Current Assembly
Replace RBCU
Replace RCSA unit

3022

PH C CURR FBK

Fault is generated
when current in Phase
C is detected and the
bypass contactor is
open

Loose CT connection
Bad RBCU
Bad CT

Check J2 connector
for proper seating
Check connector on
Current Assembly
Replace RBCU
Replace RCSA unit

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

Fault
Code

Fault Name In
Panel

69

Fault

Possible Cause

Corrective Action

3023

BYP COIL
SHORTED

Coil characteristics
are checked only on
power up and coil
current is greater than
allowable values

Shorted contactor coil


Shorted/damaged
cable
Bad RBCU

Replace RBCU
Replace RCSA unit

3024

DRV COIL
SHORTED

Coil characteristics
are checked only on
power up and coil
current is greater than
allowable values

Shorted contactor coil


Shorted/damaged
cable
Bad RBCU

Replace RBCU
Replace RCSA unit

3027

INVALID SUB
ASM

Contactor assembly
as recorded in the
RBCU unit does not
match drive
information
communicated via 485
link

RBCU unit from a


different size bypass
used to replace a
defective RBCU.
Parameters not
matched after
Firmware change.

Contact ABB at
1-800-HELP-365
Option 4

3028

EXT COMM LOSS

Time between fieldbus


messages has
exceeded timeout
interval set with
parameter 3005

Incorrect
Communication
settings in Group 51 &
53.
Poor Connections
Noise on
Communication Line

Check Group 51 & 53


Tighten Connections
Check
Communication Cable
Grounding

3029

EFB CONFIG
FILE

Error reading
configuration file for
embedded fieldbus

Internal Startup error

Cycle Power
Replace RBCU

3030

FORCE TRIP

Fault trip forced by


external fieldbus

Overriding Control
System tripped
E-Clipse unit via
fieldbus.

Check Overriding
Control System

3031
...
3033

EFB 1...EFB 3

Fault code reserved


for embedded
fieldbus.

For Bacnet: Device


object instances for
the drive and or
bypass are set greater
than 4194302 in
paramters 5011 5017
and or 5311 5317
respectively

Check Parameters
5011, 5017 and/or
5311, 5317

3034

MTR PHASE

Detects open motor


phase. Detection is
done by current
transformers in
bypass unit.

Internal problem
Cable problem
Motor problem

Check wiring in
E-Clipse Unit
Check motor cabling
Check Motor
Check if 3006 is
Disabled

3037

PCB TEMP

RBCU unit has


reached 190 degrees
Fahrenheit, 88
degrees Celsius

Cabinet cooling has


failed
Ambient conditions
too high
Bad RBCU unit

Stop drive and let cool


down and restart
Add additional cooling
Replace RBCU

ACH550 E-Clipse Bypass

70

ACH550 Installation, Operation and Maintenance Manual

Fault
Code

Fault Name In
Panel

Fault

Possible Cause

Corrective Action

3038

NO DRIVE DATA

No drive data
available (Group 112)

Bypass not able to


extract drive data on
initial power up due to:
Bad cable/connection
between drive and
bypass.
Communication
improperly set in drive
Parameter 9802.
Application Macro
improperly set in drive
parameter 9902.

Proper seating of
cable in drive and
RBCU (connector J3)
Check drive
parameter 9802
(Modbus) and 9902
(E-Clipse)
Check drive Group 53
Follow DriveLink
recovery procedure
then cycle power to
bypass.

3039

FBA PAR CONF

Non embedded
fieldbus has detected
an error in Group 51
parameters

Incorrect settings in
Group 51

Verify Group 51
parameters

3101

SFLASH
CORRUPT

Internal checksum
error

NA

Cycle power
Replace RBCU
Upgrade firmware

3102

PMAP FILE

Parameter file is
corrupt

3201

T1 OVERLOAD

T1 program cycle is
overloaded

NA

Contact ABB with


information that
proceeded fault
Cycle Power
Replace RBCU

3202

T2 OVERLOAD

T2 program cycle is
overloaded

NA

Contact ABB with


information that
proceeded fault
Cycle Power
Replace RBCU

3203

T3 OVERLOAD

T3 program cycle is
overloaded

NA

Contact ABB with


information that
proceeded fault
Cycle Power
Replace RBCU

3204

STACK
OVERFLOW

Program cycle is
overloaded

NA

Contact ABB with


information that
proceeded fault
Cycle Power
Replace RBCU

ACH550 E-Clipse Bypass

Cycle Power
Contact ABB with
information that
preceeded fault

ACH550 Installation, Operation and Maintenance Manual

Fault
Code

Fault Name In
Panel

Fault

71

Possible Cause

Corrective Action

3205

UNKNOWN CB

Bypass control board


type is unknown.

Firmware is not
compatible with
control board in
RBCU.

Firmware 93F and


greater compatible
with all RCBU
hardware.
Firmware 93D and
earlier can only be
loaded in RBCU Rev
D and earlier.

3206

UNKNOWN
DRIVE

Drive reports rating


not found in bypass
software

Drive does not match


drives configured in
bypass RBCU

Replace RBCU or
reload with most
current firmware

3207

UNKNOWN
BYPASS

NA

NA

Replace RBCU or
load most current
firmware
Contact ABB at
1-800-HELP-365
option 4
Replace RBCU or
load most current
firmware

Fault History
See page 28.
Alarm listing
The following table lists the alarms by code number and describes each.
Alarm
Code

Alarm Name In
Panel

4001

INP PHASE A
LOSS

4002

INP PHASE B
LOSS

4003

INP PHASE C
LOSS

Alarm
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3010 if the
bypass contactor is
closed
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3011 if the
bypass contactor is
closed
Alarm will occur in drive
mode. In bypass,
alarm will occur if
bypass contactor has
not closed. Unit will trip
on Fault 3012 if the
bypass contactor is
closed

Possible Cause

Corrective Action

Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J8 connector
Check yellow wire on
input block
Check incoming
voltage, phase to
ground

Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J8 connector
Check black wire on
input block
Check incoming
voltage, phase to
ground

Loose J8 connector
Loose wiring on
Contactor assembly.
Blown upstream fuse

Check J8 connector
Check red wire on input
block
Check incoming
voltage, phase to
ground

ACH550 E-Clipse Bypass

72

ACH550 Installation, Operation and Maintenance Manual

Alarm
Code

Alarm Name In
Panel

Alarm

Possible Cause

Corrective Action

4004

AUTO TRANSFER

Message is displayed
when the drive faults
and the bypass
switches to bypass
mode as configured in
Parameter 1608

Drive fault

Check drive

4005

EXT COMM ERR

Time between fieldbus


messages has
exceeded timeout
interval set with
parameter 3005

Check Group 51& 53


Tighten Connections
Check Communication
Cable Grounding

4006

Selected by PAR
1620:
RUN ENABLE
DAMPER END
SWITCH
VALVE OPENING
PRE-LUBE CYCLE

Alarm will occur when


start order is given and
the RUN Enable is not
present

Incorrect
Communication
settings in Group 51 &
53.
Poor Connections
Noise on
Communication Line
Run Enable condition is
not satisfied.
Bad 24v supply
Bad digital input

4007

PCB TEMP

RBCU unit reached


181 degrees
Fahrenheit, 83 degrees
Celsius

Cabinet cooling has


failed
Ambient conditions too
high
Bad RBCU unit

Stop drive and let cool


down and restart
Add additional cooling
Replace RBCU

4008

DRIVE SETUP

Alarm generated when


configuration of drive is
such that bypass can
not properly control the
drive. Specifically, drive
parameters
1001,1002,1601, 1608

Incorrect parameters
settings

Set Parameter 1001 to


COMM
Set Parameter 1002 to
COMM
Set Parameter 1601 to
COMM
Set Parameter 1608 to
COMM

4009

BYPASS RUN
DELAY

Alarm is generated
when a bypass start
command is issued and
there is non zero time
value in bypass
parameter 1614

NA

NA

4010

MTR OVERLOAD

Bypass warning if
motor overload
conditions exist as
defined in the drive

Drive Mode:
Bad Motor
Bad Cts
Bad RBCU
Bypass mode:
Bad motor
Bad CTs
Bad RBCU
Either mode:
low input voltage

Drive Mode:
Refer to 550 manual
for proper
troubleshooting
techniques
Bypass Mode:
Check that J2
connector is firmly
seated in RBCU
Check input voltage
Does overload
condition exist?

ACH550 E-Clipse Bypass

Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
for status of digital input

ACH550 Installation, Operation and Maintenance Manual

Alarm
Code

Alarm Name In
Panel

73

Alarm

Possible Cause

Corrective Action

4011

MTR UNDERLOAD

Alarm comes at half the


time of a mtr underload
fault. See fault 3017 for
further text

NA

4012

BYPASS
DISABLED

NA

4013

DRIVE LINK
ERROR

Alarm will be generated


if parameter 1613 is set
to Disable
Same as Fault 3019
however will occur
when not in supervisory
mode

4014

DRIVE TEST

Alarm is generated
when bypass
parameter 1617 is set
to enable

NA

Proper seating of cable


in drive and
RBCU(connector J3)
Check drive parameter
98.02 and 99.02
Check drive Group 53
Follow DriveLink
recovery procedure
NA

4015

START DRIVE 1ST

Message displayed on
initial out of box
power up sequence

NA

Run drive in Hand

4016

INP VOLTAGE
LOW

NA

Loose J7 connector
Low input voltage.
Incoming voltage has
not reached at least
155 VAC within a few
seconds of powerup

4019

OVERRIDE 1

NA

4020

OVERRIDE 2

3-Phase input voltage


has not reached a
sufficient level to
enable editing of
parameters via the
keypad. This message
is generated within a
few seconds of power
up
Alarm is generated
when Smoke Control is
active
Alarm is generated
when Firemans
Override is active

Check Parameter
0103 and 0104 for
digital input status
Check Parameter
0103 and 0104 for
digital input status

4021

Selected by PAR
1621
START ENABLE 1
VIBRATION
SWITCH
FIRESTAT
FREEZESTAT
OVERPRESSURE
VIBRATION TRIP
SMOKE ALARM
SAFETY OPEN
LOW SUCTION
PRES

Alarm will occur when


start order is given and
the RUN Enable is not
present

Parameter 3002 is the


time
Parameter 3003 is the
level
NA

Bad cable between


drive and bypass
Communication
improperly set in drive
Parameter
98.02(Modbus)
Application Macro in
99.02 set to 15 (text)

NA

Run Enable condition is


not satisfied.
Bad 24v supply
Bad digital input
24 V common is not
tied to Digital input
common on bypass
when using external 24
v supply

Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input

ACH550 E-Clipse Bypass

74

ACH550 Installation, Operation and Maintenance Manual

Alarm
Code

Alarm Name In
Panel

Alarm

Possible Cause

Corrective Action

4022

Selected by PAR
1622
START ENABLE 2
VIBRATION
SWITCH
...
LOW SUCTION
PRES

Alarm will occur when


start order is given and
the RUN Enable is not
present

Run Enable condition is


not satisfied.
Bad 24v supply
Bad digital input
24 V common is not
tied to Digital input
common on bypass
when using external 24
v supply

Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input

4023

Selected by PAR
1623
START ENABLE 3
VIBRATION
SWITCH
...
LOW SUCTION
PRES

Alarm will occur when


start order is given and
the RUN Enable is not
present

Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input

4024

Selected by PAR
1624
START ENABLE 4
VIBRATION
SWITCH
...
LOW SUCTION
PRES

Alarm will occur when


start order is given and
the RUN Enable is not
present

Run Enable condition is


not satisfied.
Bad 24v supply
Bad digital input
24 V common is not
tied to Digital input
common on bypass
when using external 24
v supply
Run Enable condition is
not satisfied.
Bad 24v supply
Bad digital input
24 V common is not
tied to Digital input
common on bypass
when using external 24
v supply

4025

LOCAL DISABLED

4026

AUTO DISABLED

4027

COMM CONFIG
ERR

Alarm is displayed if
MODE LOCK (16.29) is
set to AUTO MODE
and the Hand or Off key
is pressed
This alarm is displayed
if MODE LOCK (1629)
is set to LOCAL MODE
and the Auto key is
pressed.
Alarm is displayed if the
drive and bypass MAC
addresses are equal or
invalid.

4028

FBA PAR CONF

4029

DRIVE FAULTED

ACH550 E-Clipse Bypass

Non embedded
fieldbus has detected
an error in Group 51
parameters
The drive is faulted.

E-Clipse parameters
5002(BP MAC ID) &
5302 (DV MAC ID) are
set to the same value

Check 24 Volts on
RBCU unit
Check for 24 volts on
respective DI when
condition is satisfied
Check Parameter 0103
For status of digital
input

Change MAC address


to unique values

Verify Group 51
parameters

Reset drive

ACH550 Installation, Operation and Maintenance Manual

75

Bypass status listing


Bypass Status
(16 Characters)

Condition

Description

DRIVE/BYPASS?

DRIVE SELECTED
BYPASS SELECTED

Displays which one is selected, drive or


bypass

SAFETIES?

OPEN
CLOSED

Displays if safeties (=START ENABLE 1


and/or START ENABLE 2) have been
applied, or if they are missing

RUN PERMISSIVES?

OPEN
CLOSED

Displays if RUN ENABLE is present or not

START REQUEST?

NOT PRESENT
PRESENT

Displays if start request has been applied to


the system

AUTO TRANSFER?

NOT TRANSFERRED
TRANSFERRED

Displays if the system is in Auto Transfer


state or not. Does not reflect to PAR 16.08
AUTO XFER value itself

BYP OVERRIDE 1?

NOT ACTIVATED
ACTIVATED

Status of Override 1

BYP OVERRIDE 2?

NOT ACTIVATED
ACTIVATED

Status of Override 2

DRIVE FAULTED?

NO
YES

Displays if drive is faulted or not

BYPASS FAULTED?

NO
YES

Displays if bypass is faulted or not

SYSTEM STARTED?

NO
YES

Displays if system is started or not

SYSTEM RUNNING?

NO
YES

Displays if system is running or not

BYPASS ALARMS?

NO ALARMS
ALARM ACTIVE

Displays if there is an active alarm(s) in


bypass or not

HAND/OFF/AUTO?

OFF MODE
HAND MODE
AUTO MODE

Displays operating mode of the bypass OFF, HAND or AUTO

ACH550 E-Clipse Bypass

76

ACH550 Installation, Operation and Maintenance Manual

Error messages
#

Error Message

Description

CANT EDIT
PAR IS READ ONLY

Try to save value (=press the ENTER key in Parameter Edit State) of a readonly parameter. E.g. try to change value PAR 01.02 INPUT VOLT

CANT EDIT
WHEN STARTED

Try to change value of a parameter, which is allowed to be changed only when


system is not started. E.g. PAR 16.02 RUN ENABLE

CANT EDIT
UP+DOWN ONLY

Try to change value of a reset only parameter other than zero. UP+DOWN
buttons must be pressed simultaneoulsy for requesting default value of the
PAR on the display (value zero), and after that ENTER pressed for saving it
(reset the parameter). E.g. PAR 04.01 LAST FAULT

CANT EDIT
INP VOLTAGE LOW

Input voltage too low. Changing of parameters prohibited since system cannot
save values to nv-mem w/ insufficient voltage.

CANT EDIT
PAR IS HIDDEN

Try to save value (=press the ENTER key in Parameter Edit State) of a hidden
parameter. Should not be possible. If hidden parameters are turned visible, this
message is not given.

CANT EDIT
UNDER LO-LIMIT

Try to save value which is over LO-LIMIT of the parameter. Should not be
possible when changing parameters from control panel.

CANT EDIT
UNDER HI-LIMIT

Try to save value which is over HI-LIMIT of the parameter. Should not be
possible when changing parameters from control panel.

CANT EDIT
ENUM VAL ONLY

Try to save value which is out of enumerated value list. Should not be possible
when changing parameters from control panel.

CANT EDIT
NO DEFAULT

Try to request default value (=press UP and DOWN buttons simultaneously) for
a parameter which is defined not to have a default value. Should not be
possible when changing parameters from control panel.

10

CANT EDIT
TRY AGAIN.

Parameter system is busy, e.g. application macro change is in process at the


same time when someone is trying to save a value for a parameter. Should not
be possible when changing parameters from control panel.

Maintenance
See Maintenance for the ACH550-UH on page 31.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual

77

ACH550-PCR/PDR

Installation
This information is unique to ACH550 input disconnect configurations (PCR or PDR).
The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive
packaged with an input disconnect switch or circuit breaker. Refer to the Installation
instructions on page 3, for all other information. Failure to observe the warnings
and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety on page 2.

WARNING! When the ACH550 with Input Disconnect is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not
make any connections when the ACH550 with Input Disconnect is connected to the
line. Disconnect and lock out power to the drive before servicing the drive. Failure to
disconnect power may cause serious injury or death.

1. Install wiring
WARNING!
Metal shavings or debris in the enclosure can damage electrical equipment and
create a hazardous condition. Where parts, such as conduit plates require cutting
or drilling, first remove the part. If that is not practical, cover nearby electrical
components to protect them from all shavings or debris.
Do not connect or disconnect input or output power wiring, or control wires, when
power is applied.
Never connect line voltage to drive output Terminals T1, T2, and T3.
Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of the
unit. Disconnect motor wires before taking any measurements in the motor or
motor wires.
Make sure that power factor correction capacitors are not connected between the
drive and the motor.

ACH550-PCR/PDR

78

ACH550 Installation, Operation and Maintenance Manual

Connection diagrams standard drive with input disconnect (wall mounted)


The following figure shows the Standard Drive with Input Disconnect (wall mounted)
wiring connection points.
UL Type / NEMA 1 & 12
Vertical Construction
Enclosures

ACH550

UL Type / NEMA 1 & 12


Hinged Door Wall Mount
Enclosures

I/O Conduit
(Top)

Ground
Lug(s)

Motor
Terminals
Gnd
Input Power
Terminals
Disconnect Switch
or Circuit Breaker

Motor
Terminals

Input Power
Terminals
I/O Conduit
(Bottom)

UL Type / NEMA 3R
Enclosures
Fan/Space Heater
Power Supply &
Control Assembly

Disconnect Switch
or Circuit Breaker
ACH550
Input Power
Terminals

Motor
Terminals

I/O Conduit
(Bottom)

Ground
Lug

Note: Type 3R enclosures are designed to be mounted on a wall. For 3R enclosure


back plates which maintain 3R integrity when the enclosure is mounted on an open
rack system, contact your ABB HVAC Drives Distributor.

ACH550-PCR/PDR

ACH550 Installation, Operation and Maintenance Manual

79

Connection diagrams standard drive with input disconnect (floor mounted)


Floor mounted UL Type / NEMA 1 & 12 Drive with Input Disconnect units are
configured for wiring access from the top and include a removable conduit mounting
plate. The following figure shows the wiring connection points.
ACH550

Ground Lug
Bar

Motor
Terminals

Input Power
Terminals

Disconnect Switch
or Circuit Breaker

ACH550-PCR/PDR

80

ACH550 Installation, Operation and Maintenance Manual

Line input connections standard drive with input disconnect configurations


Connect input power to the terminals of the disconnect switch or circuit breaker.
Connect the equipment grounding conductor to the ground lug at the top of the
enclosure. The figure below shows the connection points for Standard Drive with
Input Disconnect configurations.
UL Type / NEMA 1 & 12
Vertical Construction
Enclosures

UL Type / NEMA 1 & 12


Hinged Door Wall Mount
Enclosures

UL Type / NEMA 1 & 12


Floor Mount
Enclosures

Input
Power

ACH550

Ground Lug
Bar

Motor
Terminals

Input Power
Terminals
Disconnect Switch
or Circuit Breaker

Input
Power

Dashed line is ground run.

Note: The terminals on disconnect switches for the following rated ACH550-PDR
products is 7 in-lbs. Do not use a power driver or over tighten to prevent breaking
screw heads or stripping the terminal.
230 VAC
-04A6-2
-06A6-2
-07A5-2
-012A-2
-017A-2
-024A-2
-031A-2

ACH550-PCR/PDR

460 VAC
-03A3-4
-04A1-4
-06A9-4
-08A8-4
-012A-4
-015A-4
-023A-4

600 VAC
-02A7-6
-03A9-6
-06A1-6
-09A0-6
-011A-6
-017A-6

ACH550 Installation, Operation and Maintenance Manual

81

Power connection terminals


The following tables show maximum wire size and required tightening torque for
incoming power, grounding and motor terminals.

Power Wiring Data2

208/240 Volt

HP

Type Code1

Base
Circuit
Drive Breaker
Frame
UL Type/
Size
NEMA
1 &12

ACH550-PxR-04A6-2

R1

1.5

ACH550-PxR-06A6-2

R1

ACH550-PxR-07A5-2

R1

ACH550-PxR-012A-2

R1

ACH550-PxR-017A-2

R1

7.5

ACH550-PxR-024A-2

R2

10

ACH550-PxR-031A-2

R2

15

ACH550-PxR-046A-2

R3

20

ACH550-PxR-059A-2

R3

25

ACH550-PxR-075A-2

R4

30

ACH550-PxR-088A-2

R4

40

ACH550-PxR-114A-2

R4

50

ACH550-PxR-143A-2

R6

60

ACH550-PxR-178A-2

R6

75

ACH550-PxR-221A-2

R6

100

ACH550-PxR-248A-2

R6

Circuit
Breaker
UL Type
/ NEMA
3R

Disconnect
Switch
UL Type/
NEMA
1&12

#10
35 in-lbs

#10
35 in-lbs

#10
7 in-lbs

#10
7 in-lbs

#10
35 in-lbs

#10
35 in-lbs

#6
45 in-lbs

#6
45 in-lbs

#8
7 in-lbs

#8
7 in-lbs

#6
35 in-lbs

#6
35 in-lbs

#3
50 in-lbs

#3
50 in-lbs

#4
18 in-lbs

#4
18 in-lbs

#3
50 in-lbs

#3
50 in-lbs

#1
50 in-lbs

#1
50 in-lbs

#1
55 in-lbs

#1
55 in-lbs

#1/0
70 in-lbs

#1/0
70 in-lbs

#2
50 in-lbs

#2
50 in-lbs

300 MCM
275 in-lbs

300 MCM
200 in-lbs

350 MCM
274 in-lbs

300 MCM
200 in-lbs

Disconnect
Ground
Switch
Lugs
Motor
UL Type/
UL
Type/
Terminals
NEMA
NEMA
3R
1&12

Refer to
Drives
power
connection
terminals

3 x #3/0
250 in-lbs
2 x 250
MCM
274 in-lbs

2 x 250
MCM
275 in-lbs

2 x 250 MCM
274 in-lbs

2 x 250 MCM
275 in-lbs

Ground
Lugs
UL Type
/ NEMA
3R

#2/0
275 in-lbs

350 MCM
100 in-lbs

1. PxR represents both PCR and PDR.


2. Torque values shown relate to current production. Check component labels on previously installed
units for required tightening torque.

ACH550-PCR/PDR

82

ACH550 Installation, Operation and Maintenance Manual

Power Wiring Data2

480 Volt
Circuit
Base
Drive Breaker
Frame
UL
Type/
Size
NEMA
1 &12

HP

Type Code1

1/1.5

ACH550-PxR-03A3-4

R1

ACH550-PxR-04A1-4

R1

ACH550-PxR-06A9-4

R1

ACH550-PxR-08A8-4

R1

7.5

ACH550-PxR-012A-4

R1

10

ACH550-PxR-015A-4

R2

15

ACH550-PxR-023A-4

R2

20

ACH550-PxR-031A-4

R3

25

ACH550-PxR-038A-4

R3

30

ACH550-PxR-045A-4

R3

40

ACH550-PxR-059A-4

R4

50

ACH550-PxR-072A-4

R4

60

ACH550-PxR-078A-4

75

Circuit
Breaker
UL
Type/
NEMA
3R

#10
35 in-lbs

#10
35 in-lbs

#6
45 in-lbs

#6
45 in-lbs

#3
50 in-lbs

#3
50 in-lbs

#1
50 in-lbs

#1
50 in-lbs

Disconnect Disconnect
Ground
Switch
Switch
Lugs
Motor
UL Type/
UL Type/
UL
Type/
Terminals
NEMA
NEMA
NEMA
1&12
3R
1&12

#10
7 in-lbs

#10
7 in-lbs

#8
7 in-lbs

#8
7 in-lbs

#4
18 in-lbs

#4
18 in-lbs

#1
55 in-lbs

#1
55 in-lbs

R4

#1
50 in-lbs

#1
62 in-lbs

ACH550-PxR-097A-4

R4

#1/0
70 in-lbs

#1/0
70 in-lbs

100

ACH550-PxR-125A-4

R5

125

ACH550-PxR-157A-4

R6

300 MCM
275 in-lbs

300 MCM
200 in-lbs

150

ACH550-PxR-180A-4

R6

200

ACH550-PxR-246A-4

R6

2 x 250 MCM
274 in-lbs

500 MCM
274 in-lbs

250

ACH550-PxR-316A-4

R8

300

ACH550-PxR-368A-4

R8

350

ACH550-PxR-414A-4

R8

400

ACH550-PxR-486A-4

R8

450

ACH550-PxR-526A-4

R8

500

ACH550-PxR-602A-4

R8

550

ACH550-PxR-645A-4

R8

350 MCM
274 in-lbs

300 MCM
200 in-lbs

2 x 250
MCM
274 in-lbs

500 MCM
274 in-lbs

2 x 500
MCM
274 in-lbs

Ground
Lugs
UL Type
/ NEMA
3R

#10
35 in-lbs

#10
35 in-lbs

#6
35 in-lbs

#6
35 in-lbs

#3
50 in-lbs

#3
50 in-lbs

#1
50 in-lbs

#1
50 in-lbs

Refer to
Drives
power
connection
terminals

#2
50 in-lbs
3 x #3/0
250 in-lbs

#2/0
375 in-lbs
350 MCM
100 in-lbs

2 x 500 MCM
274 in-lbs
5 Bus Bar
Holes
(13/32)

3 x 400
MCM
375 in-lbs

3 x 400 MCM
375 in-lbs

1. PxR represents both PCR and PDR.


2. Torque values shown relate to current production. Check component labels on previously installed
units for required tightening torque.

ACH550-PCR/PDR

ACH550 Installation, Operation and Maintenance Manual

83

Power Wiring Data2

600 Volt

HP

Type Code1

Frame
Size

ACH550-PxR-02A7-6

R2

ACH550-PxR-03A9-6

R2

ACH550-PxR-06A1-6

R2

7.5

ACH550-PxR-09A0-6

R2

10

ACH550-PxR-011A-6

R2

15

ACH550-PxR-017A-6

R2

20

ACH550-PxR-022A-6

R3

25

ACH550-PxR-027A-6

R3

30

ACH550-PxR-032A-6

R4

40

ACH550-PxR-041A-6

R4

50

ACH550-PxR-052A-6

R4

60

ACH550-PxR-062A-6

R4

75

ACH550-PxR-077A-6

R6

100

ACH550-PxR-099A-6

R6

125

ACH550-PxR-125A-6

R6

150

ACH550-PxR-144A-6

R6

Circuit
Breaker
UL Type
/ NEMA
1 &12

Circuit
Breaker
UL
Type
/ NEMA
3R

#6
62 in-lbs

#6
62 in-lbs

#3
62 in-lbs

#3
62 in-lbs

#1
62 in-lbs

350 MCM
274 in-lbs

#1
62 in-lbs

300 MCM
275 in-lbs

Disconnect Disconnect
Switch
Switch
Motor
UL Type
UL Type
Terminals
/ NEMA
/ NEMA
3R
1&12

#8
7 in-lbs

#8
7 in-lbs

#4
18 in-lbs

#4
18 in-lbs

#1
55 in-lbs

#1
55 in-lbs

#1
62 in-lbs

#1
62 in-lbs

#1/0
70 in-lbs

#1/0
70 in-lbs

300 MCM
275 in-lbs

300 MCM
200 in-lbs

Refer to
Drives
power
connection
terminals

Ground
Lugs
UL Type
/ NEMA
1&12

Ground
Lugs
UL Type
/ NEMA
3R

#6
35 in-lbs

#6
35 in-lbs

#3
50 in-lbs

#3
50 in-lbs

#2
50 in-lbs

3 x #3/0
250 in-lbs

#2
50 in-lbs

#2/0
375 in-lbs

1. PxR represents both PCR and PDR.


2. Torque values shown relate to current production. Check component labels on previously installed
units for required tightening torque.

ACH550-PCR/PDR

84

ACH550 Installation, Operation and Maintenance Manual

UL Type / NEMA 3R
Enclosures

Input
Power

WARNING! Check the motor and motor wiring insulation before connecting the
ACH550 to line power. Follow the procedure on page 12. Before proceeding with the
insulation resistance measurements, check that the ACH550 is disconnected from
incoming line power. Failure to disconnect line power could result in death or serious
injury.

Note: For the remainder of the wiring (motor and control wiring) refer to page 7.

ACH550-PCR/PDR

ACH550 Installation, Operation and Maintenance Manual

85

Operation
This information is unique to ACH550 input disconnect configurations (PCR or PDR).
Refer to the Operation instructions on page 21 for all other information.
Input disconnect configuration
The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive
packaged with an input disconnect switch or circuit breaker, and with a door
interlocked, external operating handle. The operating handle can be padlocked in
the OFF position (padlock not supplied). Enclosure options are UL Type 1, UL Type
12, and UL Type 3R (NEMA 1, NEMA 12, and NEMA 3R).
The following is a typical power diagram.
Disconnect Switch
or Circuit Breaker
3 Phase
Input Power

Drive with Input Disconnect

ACH550
Drive

Motor

ACH550-PCR/PDR

86

ACH550 Installation, Operation and Maintenance Manual

The following shows the front view of the ACH550 Drive with Input Disconnect
standard configurations, and identifies the major components.
UL Type / NEMA 1 & 12
Vertical Construction
Enclosures

UL Type / NEMA 1 & 12


Hinged Door Wall Mount
Enclosures
ACH550 Drive
Control Panel

Operating Handle
for Disconnect Switch
or Circuit Breaker

UL Type / NEMA 3R
Enclosures

ACH550 Drive
Control Panel with
Hinged Cover

ACH550-PCR/PDR

UL Type / NEMA 1 & 12


Floor Mount
Enclosures

ACH550 Installation, Operation and Maintenance Manual

87

Maintenance
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB for ACH550
enclosures in addition to the intervals on page 31.
Maintenance

Configuration

Interval

Instruction

Check/replace hinged Hinged door wall


door wall mount
mount UL Type /
enclosure inlet air filter NEMA 12
enclosures

Check every 3
months. Replace
as needed.

Enclosure air filter replacement


UL Type / NEMA 12 hinged door
wall mount enclosures on
page 87.

Check/replace floor
mount enclosure inlet
air filter

Floor mount UL
Type / NEMA 12
enclosures

Check every 3
months. Replace
as needed.

See Maintenance on page 34 and


Enclosure air filter replacement
UL Type / NEMA 12 hinged door
wall mount enclosures on page 87.

Check/replace NEMA UL Type / NEMA


3R enclosure air filters 3R enclosures PX3R-5 and
higher

Check every 3
months. Replace
as needed.

See PX3R dimensional


information.

Check/replace floor
mount enclosure
exhaust air filter.

Check every 6
months. Replace
as needed.

See Maintenance on page 35 and


Enclosure air filter replacement
UL Type / NEMA 12 hinged door
wall mount enclosures on page 87.

Floor mount UL
Type / NEMA 12
enclosures

Enclosure air filter replacement UL Type / NEMA 12 hinged door wall mount
enclosures
Filter material
Material
American Air Filter (358-35-06A-12A)

Filter Type
Polykleon White 12.7 mm x 152.4 mm x 304.6 mm stk

This procedure applies to drive with input disconnect configurations in UL Type /


NEMA 12 hinged door wall mount enclosures. This filter is located at the bottom of
the enclosure. Use the following procedure to check and replace filters.
1. On the enclosure, remove the screw holding the filter bracket in place.
2. Slide the filter bracket forward until the hooks on the bracket clear the slots on the
enclosure base. This step allows the filter and bracket to drop free from the
enclosure.
Back of Enclosure
Enclosure
Slot
Hook

Mounting
Screw

Filter Bracket

ACH550-PCR/PDR

88

ACH550 Installation, Operation and Maintenance Manual

3. Lift the filter out of the filter bracket and replace as appropriate.
4. With the filter in the filter bracket, align the hooks on the bracket with the slots in the
enclosure base, and press the hooks up into the slots.
5. Slide the filter bracket back, making sure that the hooks catch on the enclosure.
6. Replace the mounting screw. Tighten until the gasket on the bracket is about 50%
compressed.
Enclosure air filter replacement UL Type / NEMA 12 floor mount enclosures
Filter material
Enclosure Type
UL Type / NEMA 12

Inlet (door)
3AUA0000006723 (qty 1)

Outlet (roof)
3AUA0000006722 (qty 2)

Note: When installing the filter media, the white side must face the outside of the
cabinet and the colored side must face the inside of the cabinet. Refer to page 34.

Diagnostics

3AUA0000081824 REV A
Effective: 08/01/2010

Refer to the Diagnostics instructions on page 24.

ABB Inc.
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone +1 800 752-0696
Fax
+1 262 785-0397
Internet
www.abb.us/drives

TAB 3

Installation and Maintenance Manual

Skyline Air Handler

IM 777-5
Group: Applied Air Systems
Part Number: IM 777
Date: May 2010

Models OAC/OAH 003G 090G

2010 McQuay International

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving and Handling . . . . . . . . . . . . . . . . . . . . 3
Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . 4
Service Clearances . . . . . . . . . . . . . . . . . . . . . . . 4
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Curb Mounting and Unit Leveling . . . . . . . . . . . . . 4
Assembling Sections . . . . . . . . . . . . . . . . . . . . . . 5
Shipping Sections . . . . . . . . . . . . . . . . . . . . . . 5
Panels, Frame Channels, and Doors . . . . . . . . . . 7
Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 7
Frame Channel Removal . . . . . . . . . . . . . . . . 7
Access Doors and Panels . . . . . . . . . . . . . . . . 7
Fan Section Doors . . . . . . . . . . . . . . . . . . . . . 7
Injected-Foam Insulated Panels . . . . . . . . . . . 8
Field Mounting Junction Boxes and
Other Components . . . . . . . . . . . . . . . . . . . . . . . . 8
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dampers and Hoods . . . . . . . . . . . . . . . . . . . . . . 9
Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . 9
Face and Bypass Section Mounting. . . . . . . . . . 10
Piping Vestibules . . . . . . . . . . . . . . . . . . . . . . . . 10
Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water Cooling Coils . . . . . . . . . . . . . . . . . . . 10
Direct Expansion Coils . . . . . . . . . . . . . . . . . 10
Steam Coils. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water Heating Coils . . . . . . . . . . . . . . . . . . . 13
Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . 13
Internal Isolation Assembly Adjustment . . . . . . . 14
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . 16

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . 17
Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . 17
Before Starting the Unit: . . . . . . . . . . . . . . . . . . 17
Fan Wheel Alignment . . . . . . . . . . . . . . . . . . 18
Operating Limits. . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . 21
Vibration Causes . . . . . . . . . . . . . . . . . . . . . 21
Service and Maintenance . . . . . . . . . . . . . . . . . . . 22
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . 22
Ball Bearing Lubrication. . . . . . . . . . . . . . . . . . . 22
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . 22
Fan Shaft Bearings. . . . . . . . . . . . . . . . . . . . 22
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
VM and VP Variable Pitch Key Type Sheaves 23
LVP Variable Speed Sheaves . . . . . . . . . . . 24
MVP Variable Speed Sheaves . . . . . . . . . . . 25
Fan Drive Belt Adjustment . . . . . . . . . . . . . . 27
Front Load Filter Option. . . . . . . . . . . . . . . . . . . 28
Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Winterizing Water Coils . . . . . . . . . . . . . . . . 29
Removing and Replacing Components . . . . . . . 29
Removing the Fan Section . . . . . . . . . . . . . . 29
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 31
Service and Warranty Procedure . . . . . . . . . . . . 32
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Warranty Return Material Procedure . . . . . . . . . 32
Check, Test, and Start Procedure Form . . . . . . . 33
Quality Assurance Survey Report. . . . . . . . . . . . 35

Introduction
Introduction

General Information

inspect all units for shipping damage. Report damage


immediately to the carrier and file a claim.

The system design and installation must follow accepted industry


practice as described in the ASHRAE Handbook, the National
Electric Code, and other applicable standards. Install this
equipment in accordance with regulations of authorities having
jurisdiction and all applicable codes.

2 Skyline air handler units are constructed of galvanized or

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

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, fins, clips, and such items inherently have
sharp edges; the installer should exercise caution.
CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.

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.
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, unless the unit has a curb ready base. Units
require caulk sealant between sections.

Unit Storage

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

Receiving and Handling


1 Carefully check items against the bills of lading to verify

all crates and cartons have been received. Carefully

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.

Nomenclature
OAH 003 G
Model
OAH = Outdoor air handler
OAC = Outdoor air component

Nominal Unit Size


(nominal square foot of coil)
003, 004, 006, 008, 010, 012, 014, 017, 021, 025,
030, 035, 045, 055, 065, 080, 085, 090
Vintage of McQuay Air Handling Unit

D A C
Unit Cross Section
C = Standard unit cross section
M = Custom size cross section

Motor Location
A = Motor along side of fan housing
D = Motor downstream of belt drive plenum fan
F = Motor on inline fan
G = Motor downstream of direct drive plenum fan
T = Motor behind twin housed fans
Unit Type/Coil Position
B = Blow-thru cooling coil location
D = Draw-thru cooling coil location
H = Heating only
V = Vent only

McQuay IM 777

Mechanical Installation
Mechanical Installation

Service Clearances

Rigging

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 spaceat least equal to the
length of the coilon the side of the unit for coil removal. See
Figure 1 for servicing space requirements.

Skyline 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. Units are provided with a factory-installed base rail
and can be lifted using the 2" diameter lifting holes located in
the corners of each shipping section. 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 unit.

Maintain at least 54" of clearance in front of electrical power


devices. Electrical power devices that are mounted on the side
of the unit typically are up to 12" deep (Figure 2).

Figure 3: Unit and Section Rigging

Figure 1: Servicing Space Requirements


4 .0 0 " b a s e r a il e x te n s io n

W id th

3 0 .0 0 "

W id th o f c o il s e c tio n

4 .0 0 "

W id th o f
fa n s e c tio n

3 0
.0 0
"

H e ig h t

Figure 2: Service Clearance for Electrical Power Devices

Curb Mounting and Unit Leveling


Do not place a Skyline unit over an open curb unless it is
equipped with a curb-ready base. Installation instructions for
mounting units on a roof curb are provided in IM 770. For a
copy, contact your local McQuay representative or visit
www.mcquay.com. Make provisions under the unit to divert
any moisture from entering the building below.
For units without roof curb mounting, place the equipment on
a flat and level surface. Where surface irregularities exist, shim
the base of the unit at one or more points along the length of
the rails to prevent distortion or sagging of the support rails.
Uneven or distorted sections cause misfit or binding of the
doors and panels and improper draining of drain pans
(Figure 4).

1 2 "

5 4 "

McQuay IM 777

Mechanical Installation
Figure 4: Leveling the Unit

2 Pull sections together to fasten. Use straps and a ratchet

to help pull the sections together securely. Apply sealant


to any gaps that may admit moisture.
3 Fasten base rails together first using the 3/8"-16 5"

bolts located in the splice kit provided with the unit


(Figure 7).
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.

S h im s e c tio n s u n til
th e y a r e s tr a ig h t
a n d le v e l

S h im to p r e v e n t
d is to r tio n if w id th
is o v e r 1 0 8 "

Assembling Sections
If the unit is shipped in more than one shipping section, rig
each section into position separately. Shipping sections are
provided with a connection splice joint attached on the leaving
air side of the shipping section that seals against the frame
channel on the entering-air side of the adjoining. The splice
joint is insulated and provides an air-tight seal between two
sections once they are assembled together. 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 8).

b If desired, shipping sections for non curb-ready units

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.
c Handle units with curb-ready bases and vestibules so

the lifting bracket can be removed after the unit is


placed on the curbing.
Note: Remove the lifting bracket that projects inward over
the curbing. Save the self tapping screws. When the
adjacent section is placed in position, use self
tapping screw to secure the bases together.
Figure 6: Remove Vestibule Lifting Bracket

Shipping Sections
1 Caulk all assembly joints of the unitBefore joining the

sections, apply at least 1/4 inch diameter bead of sealant


to the mating faces of the cabinet. Use the splice joint as
a guide for applying the sealant (Figure 5).
Figure 5: Apply Sealant to Mating Faces

1 /4 " d ia m e te r
b e a d c e n te re d
in fa c e o f
c le a r a n c e
U s e S p lic e
J o in t a s a
g u id e

McQuay IM 777

R e m o v a b le
L iftin g B r a c k e t

Mechanical Installation
Figure 7: Fasten Bottom of Section

Figure 8: Internal Fastening

D
Gasket
A
S p lic e C o lla r
m u s t b e a lig n e d
to s e a l to g a s k e t.

3/8" x 1" Bolt and Nut

1 Check that the sealant is compressed between the mating


d A length of D gasket is attached to each section

(Figure 7). This gasket MUST be installed to the unit


base section.
IMPORTANT
The gasket is to be installed in an arc shape with the ends
lower than the center, so that any moisture that may reach the
gasket will be drained to the outside of the unit.
e Handle units with curb-ready bases and vestibules so

the lifting bracket can be removed after the unit is


placed on the curbing.
Note: Remove the lifting bracket that projects inward over
the curbing. Save the self tapping screws. When the
adjacent section is placed in position, use self
tapping screw to secure the bases together.

channels when the unit sections are joined. Touch up any


places where gaps are noted.
2 After sections are seated tightly together, slip the splice

cap over the top panel flanges. Bend the ends of the
splice cap down to secure in place (Figure 9).
3 Assemble the small splice plate at the top rail to secure

the sections together at the top. Use 5/16" bolts


(Figure 9).
Figure 9: Splice Cap and Splice Plate
S lid e S p lic e C a p o n
a n d b e n d e n d s d o w n

5 /1 6 - 1 8 B o lt

5 /1 6 -1 8 N u t

S p lic e
P la te

McQuay IM 777

Mechanical Installation
Panels, Frame Channels, and Doors
Panel Removal

that require the use of tools to access compartments


containing moving parts or electrical wiring. See
Figure 11.
1 Remove padlock if one is present.

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.

CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.

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 10).

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

Figure 10: Removing Panel Screws


Remove any
panel screws that
engage frame

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


dendomagger lunit.
2 Insert 1/2" socket into cup and rotate 1/4 turn clockwise

as shown in Figure 11. 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
Remove panel
to remove frame

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 11: Opening Fan Section Door

Do Not Rotate Cup

Access Doors and Panels


For routine maintenance, access normally is obtained through
access doors or by removing side panels. Removing all flat
head fasteners along the sides of a panel allow it to be
removed.
Fan and filter sections are always provided with a service door
on one side of the unit. If requested on order, 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.

Jam
Nuts

Fan Section Doors


Note: Opening fan section doors requires using a 1/2" socket
wrench, which satisfies ANSI standards and other codes
McQuay IM 777

View from inside door

OPEN

Mechanical Installation
Injected-Foam Insulated Panels
Skyline air handlers now 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.

Figure 12: Cutting/Sealing Injected-Foam Insulated Panels


Seal completely with silicone
sealant or duct seal compound
Cut hole from both sides of panel

Panel Cutting Procedure


1 Determine the number and location of holes required for
electrical conduit, piping, and control wiring as follows:
a Check that adequate space is available inside the unit

Prop 65Substances 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.

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 it is airtight, watertight,
and so that there is no exposed insulation.
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 fume et les flammes peuvent
endommager le matriel et causesr des
blessures graves ou la mort.
Avant dutiliser le dispositif, obturer tous les
trous de passage de tubulures et de fils
mnags dans les panneaux intrieurs et
extrieurs au moyen dune pte base de
silicone ou dun mastic dtanchite
conduits de qualit industrielle.
Ne pas se servir dun chalumeau coupeur ni
exposer les pannequx une flamme nue
pour ne pas risquer de les endommager.

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.

Duct Connections
Use flexible connectors on the outlet and inlet duct
connections of all units. Do not position down flow fans over
air ducts that are routed down into the building. Use a
discharge plenum when bottom connections are necessary
(Figure 13).
Figure 13: Discharge Plenum

D is c h a r g e
P le n u m

McQuay IM 777

Mechanical Installation
If the unit has a top mixing box or economizer damper or a top
duct connection, field fabricate and install flashing to divert
moisture from the connection. The flashing must lap over the
standing seams of the top panels. The flashing also must lap
over the side edges of the unit (Figure 14).

Figure 16: Field-Installed Barrier Between Hoods

Figure 14: Flashing Over Top Panels and Sides of Units


In ta k e
F la s h in g

F la s h in g
D u c t

U n it to p
p a n e l

B a r r ie r
E x h a u s t

F la s h in g

F la s h in g

D u c t

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.

Dampers and Hoods


Side dampers may be provided in the mixing box and
economizer sections of units. When dampers are provided, a
removable panel is located above the weather hood to provide
access to the damper drive shaft. Other access may be
available depending on the specific construction of the unit
(Figure 15).
Figure 15: Filler Panel Over the Weather Hood

Note: Damper blades are at full flow when open to 70 degrees.


Do not open blades further than 70 degrees.

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.

Remove screws
and panel to access
damper control shaft.

Hood

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 larbre est de 205po/lb. Une plus grande rotation
(ou torque) peut endommager lquipement.

When units are ordered with exhaust hoods and intake hoods
adjacent to each other, install a field-supplied barrier to
prevent recirculation of exhaust air into the intake openings.
(Figure 16).

McQuay IM 777

Mechanical Installation
Face and Bypass Section Mounting

Piping and Coils

Internal and external face and bypass sections are mounted


together using the instructions for horizontal components and
do not require additional instruction. Skyline air handlers are
provided with a bypass duct that is integral to the unit
construction and requires no field assembly.

When designing and installing piping:

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.

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

Face and bypass dampers have a torque requirement of


10 in-lbs per square foot of damper face area.

Note: Use glycol in water coils for outdoor air handlers. Power
failures and other mechanical issues can expose coils to
freezing temperatures.

Piping Vestibules

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.

For units that include a piping vestibule, cut the openings for
routing the field piping as required in the field. Carefully seal
passages cut through the panels to prevent air leakage. A
single metal thickness pan is provided in the bottom of the
curb-mounted vestibule. The pan can be removed if necessary.
If holes are cut into the pan for a piping passage, seal the holes
to prevent moisture leakage (Figure 17).
Figure 17: Seal Holes for PipingCurb Mounted Units

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
located outside the unit and connected directly to the
distributor (except on units with piping vestibules). Do not
apply heat to the body of the expansion valve.

Seal holes
cut for piping

For units with standard base rails, the vestibule is open to the
coil section; therefore, seal all holes to prevent air leakage.
Figure 18: Seal Holes for PipingStandard Base Rail Units

The thermostatic expansion valve must be the external


equalizer tube type. Connect the 1/4-inch diameter external
equalizer tube provided on the coil to the connection on the
expansion valve.
Use care when piping the system, making sure all joints are
tight and all lines are dry and free of foreign material. For
typical refrigerant piping, see condensing unit product
manual.

Seal holes
cut for piping

10

McQuay IM 777

Mechanical Installation
Steam Coils

Multiple coil installationindividually trap each coil or


group of coils.

Piping (see Figure 19)


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.

Coils in seriesuse separate traps for each coil, or a bank of


coils.

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 in parallela single trap can be used, but an individual


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.
Avoid freezing conditions (entering air temperatures below
35F).

Coils
Pitch all steam coils in units toward the return connection.

McQuay strongly recommends 5JA, 8JA, 5RA and 8RA


coils.

Do not drip supply mains through the coil.

Supply 5 psi steam to coils at all times.

Do not attempt to lift condensate when using modulating or


on/off control.

Do not use modulating valves. Provide control by face and


bypass dampers.

Install vacuum breakers on all applications to prevent


retaining condensate in the coil. Generally, connect the
vacuum breaker 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.

Consider using two or three coils in series with two position


steam control valves on the coil or coils that handle 35F or
colder air. Use a modulating valve on the downstream coil to
provide the desired degree of control.

Traps
Note: Do not place steam traps outdoors.

Size traps in accordance with the manufacturers


recommendations. Make sure the required pressure
differential is always available. Do not undersize.

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
interruption in the steam pressure. Estimate three feet for
each 1 psi of trap differential required.

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.

On startup, admit steam to coil ten minutes before admitting


outdoor air.

Use bucket traps for on/off control only.

Close fresh air dampers if steam supply pressure falls below


the minimum specified.

Locate traps at least 12 inches below the coil return


connection.

McQuay IM 777

11

Mechanical Installation
Figure 19: Piping Arrangements

Float and
thermostatic trap

Check Valve

Strainer

Control valve
modulating
two position

Gate Valve

High Pressure (over 25 psi)


Vacuum breaker
1/2" check valve

Steam main
Vacuum breaker
1/2" check valve

1/4" petcock
for continuous
air venting

Steam main

Return main

1"
min.

12" min.

1/4" petcock
for continuous
air venting

High pressure
float or bucket
trap

1" min.
12" min.
High pressure
bucket trap

Full size of
return conn.

Return main

5TA, 8TA, or 5HA coils. Condensate is lifted to overhead return


main

5GA or 8GA coils. Note that the


addition of a vacuum breaker to
permit the coil to drain during
shutdown.

Low Pressure (to 25 psi)


Steam main

Steam main

Vacuum breaker
1/2" check valve

Vacuum breaker
1/2" check valve

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


12" min.
Steam main

Return main
Vacuum breaker
1/2" check valve

5JA or 8JA coil. Installed in series.


Note that each coil must have a
separate control valve and trap.

12" min.

Return main

5RA, 8RA, or 5SA coils. Banked two


high, individual trapping of each coil as
shown is preferred.

Return main
Full size of
return conn.

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

12

McQuay IM 777

Mechanical Installation
Water Heating Coils

Figure 20: 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.

Pressure (P)
at the drain pan

2P

ATTENTION
Si linstallation, lutilisation ou lentretien des serpentins
de chauffage eau sont inadquats, ceci endommagera
lquipement. Lire et suivre attentivement les instructions.

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.

2P

Note: The door panels on some applications have a close


clearance over the drain pipes. Extend the drain fitting
with a coupling if necessary for door clearance
(Figure 21).
Note: Use material that can withstand freezing temperatures
for outdoor drain traps.
Note: Drain traps that dry out can allow cold air to seep into the
equipment.
Figure 21: Extend Drain Fitting for Door Clearance

Follow recommendations of the control manufacturer


regarding types, sizes, and installation of controls.
Do not use hot water coils with entering air below 40F.
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.

C le a r a n c e

To prepare coils for winter operation, see Winterizing Water


Coils page 29.

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 20).

McQuay IM 777

D r a in

13

Mechanical Installation
Internal Isolation Assembly
Adjustment

Table 2: Motor Behind Fan Spring Mount Adjustments

On units with internally isolated fan and motor assemblies, the


assemblies are secured for shipment. with a tie-down at each
point of isolation.
Before Operating the Unit:
Remove the shipping brackets and tie-down bolts (see
Figure 23 and Figure 24) 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. See Table 1 and Table 2 below. With the unit
operating at normal cfm and static pressure, all the isolators
should be at the same height opening. 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.
Table 1: Motor Beside Fan Spring Mount Adjustments
Spring mount adjustment at rest
Downblast
H

Spring mount adjustment at rest


Fan discharge
position

Top or bottom
horz. H

Downblast
H

Upblast
H

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

Unit sizes 003 035

Unit sizes 040 090


1

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

6.75

For models 040 through 090, the isolators should be at equal


For models 040 through 090, the isolators should be at equal
height during fan operation (6"). Center the fan outlet in the
outlet panel opening. If adjustment is required, loosen the cap
screw on top of the isolator assembly. Turn the adjustment nut
below the fan frame to lower or raise the fan motor and frame
assembly. Retighten the cap screw on top of the isolator
assembly.
Figure 22: Adjusting Large Spring Mount Assembly

Fan discharge
position

Top or bottom
horz. H

Upblast
H

3.75

3.75

4.25

4.25

3.75

4.25

4.25

3.75

4.25

3.75

3.75

4.25

6.00

6.75

6.75

6.50

6.75

6.75

6.50

6.75

6.75

6.00

6.75

6.75

Adjusting bolt

Unit sizes 003 035

6"

Unit sizes 040 090

14

McQuay IM 777

Mechanical Installation
Figure 23: Removing Motor Behind Shipping Brackets
Unit sizes 006 - 090

Figure 24: Removing Motor Beside Shipping Brackets


Unit sizes 006 - 090

S h ip p in g h o ld d o w n
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )

S h ip p in g b r a c k e t
r e m o v e a n d d is c a r d
( T y p ic a l 4 p la c e s )

S e e d e ta il " A "
S p r in g h e ig h t
a d ju s tm e n t s c r e w

D im

"H "

P O S 2

P O S 3
M o to r

A ir flo w
F a n
P O S 1

P O S 4
F a n is o la to r p o s itio n n u m b e r s

S h ip p in g h o ld
d o w n s c re w

S p r in g h e ig h t
a d ju s tm e n t s c r e w
S h ip p in g
b ra c k e t

D e ta il A

McQuay IM 777

15

Electrical Installation
Electrical Installation

Wiring

Figure 25: Electrical Conduit Location

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 McQuay, or by others, refer to the
specific manufacturers literature for allowable waiting periods
for discharge of capacitors. Verify capacitors have been
discharged using an appropriate voltmeter.

Fan Motor
Junction Box

ADVERTISSEMENT
Voltage de condesateur risquee de danger! dfaut de
dbrancher la puissance lectrique et de dcharger le
condensateur avant de faire le service, il peut en rsulter des
blessures srieuses et mme la mort.
Dbranchez toute puissance lectrique (incluant les
sectionneurs distance) avant de faire du service. Assurezvous de procder au cadenassage et la pose davis assurant
que la puissance ne peut tre rtablie.
Pour le variateur de frquence variable ou tout autre
composante pouvant accumuler de lnergie qui auraient t
fournis et installs par McQuay ou autres, se rfrer la
littrature spcifique du manufacturier donnant les priodes
spcifiques dattente ncessaires pour la dcharge du
condensateur. Vrifier que le condensateur est totalement
dcharg avec les voltmtres appropris.

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 lquipement.

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.
Locate electrical conduit entrances for units above the bottom
of the unit, high enough to clear components inside, but below
the bottom of the fan motor junction box (Figure 25).

16

Conduit Entrance
(typical)

CAUTION
The base section of each cabinet has a drip pan installed
below every panel that drains to the outside frame trough. Any
holes cut through the bottom of the unit must also penetrate
the drip pan. If holes are cut in the drip pan, seal them to
prevent moisture leakage.

ATTENTION
Chaque cabinet est muni dune base avec une panne
dgouttement installe en-dessous de chaque panneau qui
vacuera leau vers la gouttire extrieure. Tous les trous
percs au bas de lunit doivent pntrer la panne
dgouttement. Sil y a des trous dans la panne
dgouttement, les sceller pour empcher les fuites deau.

When the unit is provided with an external junction box and


variable frequency drive (VFD), the VFD itself will be
mounted on the drive side fan panel inside the fan cabinet.
The external junction box will provide loose wire
connection to the VFD and to the motor. An external
mounted keypad/display control box will be provided and
connected to the VFD for manual adjustment of the VFD.
When not being serviced, close and secure electrical panel
doors to prevent accidental contact with live parts and
prevent ingress of moisture and airborne contaminants.
Control wiringaccess to the VFD is through the fan
cabinet access door. Provide shielded cable only as
described in the VFD manual provided with the unit. Route
wire through panel so that it not interfere with any other
components or in the way of any access doors. Do not drill
through drip or drain pans. Refer to the VFD installation
manual provided with the unit for detailed control wiring
instructions.

McQuay IM 777

Operation Guidelines
Operation Guidelines

Startup Checks
ATTENTION
When performing startup and service, always take thorough
safety precautions. Only trained, experienced personnel should
perform these functions.
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 svres
ou mme la mort. Avant deffectuer lentretien 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.

Risques de dommages dans le moteur du ventilateur


lectrique. Si Ia temprature de lair a proximit du
ventilateurest leve, le moteurdu ventilateur lectrique peut
chauffer et brler. Sur les transmetteurs dair circulation
transversale ou les transmetteurs dont le ventilateur est en
aval de lunit de chauffage, rgler la temprature de lair
sortant de lunit de chauffage 40C (104F).

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 construction debris is removed/filters are

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

AVERTISSEMENT
Risques dincendie et dlectrocution pouvant causer des
dommages matriels, des blessures et mme la mort.
Lalimentation lectrique du moteur du ventilateur de mme
que la mise la terre du chssis du moteur doivent tre faits
conformment aux codes dinstallations lectriques 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 dincendie et dlectrocution pouvant causer des
dommages matriels, des blessures et mme la mort.
Connecter au moteur du ventilateur lectrique un dispositif de
protection contre les surcharges conforme aux codes
dinstallations lectriques en vigueur.

terminated.
4 Check that all electrical connections are tight and that the

proper voltage is connected. Phase imbalance must not


exceed 2%.
5 Check that ball bearings on the fan shaft and motor are

prelubricated and do not need grease before startup.


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 18. Torque set
screws per Table 7, page 19.
CAUTION
Equipment damage due to loose fasteners represents
improper start-up and equipment abuse. It is not covered by
the warranty.

ADVERTISSEMENT
Les dommages dus des attaches installes de faon
inapproprie reprsentent un dmarrage inadquat et un
abus dquipement. Ceci nest pas couvert par la garantie.

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 104F (40C).

1 Check alignment of fan and motor sheaves and belt tension.

Adjust if necessary. Check tightness of sheave setscrews


and/or capscrews. See Table 7, page 19.
2 Leak test the thermal system to verify that connections are

tight.
3 Check that the condensate drain is trapped.
4 Rotate the shaft by hand to be sure it is free.
Fan Startup:

Start and run fan. Observe the rotation. If the fan operates
backward, reverse two legs of the three-phase motor
connections.

McQuay IM 777

17

Operation Guidelines
Note: 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 page 23.
After the First 48 Hours of Operation:

Table 4: Wheel-to-Inlet Funnel RelationshipForward


Curved Type Fan Wheels
Forward curved
Unit sizes 003 to 035
Diameter (in)

Unit sizes 040 to 090

C (in) C (mm)

1 Disconnect and lock electrical power source.

9x4

0.25

6.35

2 Check tightness of all bearing, wheel, and sheave setscrews

9x7

0.13

3.30

(or capscrews). See Table 7, page 19.

B
A

E q u a l s p a c in g
a ll a r o u n d

0.24

6.10

22.38 (Class 1 & 2) 0.41

20 (Class 1 & 2)

10.41

0.25

6.35

10

0.22

5.59

12

0.35

8.89

30 (Class 1 & 2)

0.47

11.94

15

0.44

11.18

33 (Class 1 & 2)

0.50

12.70

18

0.25

6.35

36 (Class 1 & 2)

0.75

19.05

20 (Class 1 & 2)

0.73

8.54

22 1/2 (Class 1 & 2) 0.59

14.99

24 1/2 (Class 1 & 2) 0.56

14.22

tensioned sufficiently to slip one to two seconds at startup


perform satisfactorily, extending life and reducing vibration. If
retensioning is necessary, be certain to retain sheave
alignment.

Figure 26: Wheel-to-Inlet Tunnel RelationshipAirfoil Type


Fan Wheels (Housed)

C (in) C (mm)

9x9

3 Recheck belt tension and adjust if necessary. Belts that are

Fan Wheel Alignment

Diameter (in)

Note:

0.47

11.94

27.62 (Class 1 & 2) 0.47

25 (Class 1 & 2)

11.94

1. To obtain rated air performance, dimensional relationship must be


held.
2. Adjust dimension C by loosening wheel hub setscrews, shifting
wheel(s) axially as needed, and retightening setscrews

Figure 28: Wheel-to-Inlet Funnel Relationship13 to 36


Plenum Fans

Cross Section Reference

EQUALLY SPACED
AROUND DIAMETER

Table 3: Wheel-to-Inlet Funnel RelationshipAirfoil Type


Airfoil
B

Unit sizes 003 to 035


A
(mm)

B
(in)

B
(mm)

A
(mm)

A
(in)

B
(mm)

13.22 4.56

116

0.21

5.33 20.00 7.19

183

0.31

7.87

14.56 5.06

129

0.21

5.33 22.25 7.69

195

0.33

8.38

16.18 5.62
17.69 6.90

143

0.21

5.33 24.50 8.56

217

0.31

7.87

175

0.22

5.59 27.00 9.47

241

0.63 16.00

21.56 7.59

193

0.24

6.10 30.00 10.47

266

0.39

9.91

24.00 8.45

215

0.23

5.84 33.00 11.75

298

0.38

9.65

36.50 12.78

325

0.38

9.65

40.25 14.31

363

0.50 12.70

Dia.

Note:

A
(in)

Unit sizes 040 to 090


Dia.

A
(in)

1. To obtain rated air performance, dimensional relationship must be


held.
2. To obtain dimension A, loosen setscrews in wheel hub(s), shifting
wheel(s) axially as needed, and retightening setscrews.
3. To obtain dimension B, loosen screw and washer fasteners around
periphery of funnel(s), shifting funnel radially as required, and retorquing fasteners.

Figure 27: Wheel-to-Inlet Funnel RelationshipForward


Curved Type Fan Wheels
C

In le t
F u n n e l

18

W h e e l

In le t
F u n n e l

FROM FUNNEL END TO


FANWHEEL OPENING END
A

Table 5: Wheel-to-Inlet Funnel Relationship13 to 36


Plenum Fan
Wheel-Funnel Parameters
Size

13

0.25

0.91

3.50

15

0.25

0.91

3.50

16

0.25

0.91

3.50

18

0.38

0.86

3.88

20

0.42

1.11

3.88

22

0.45

1.11

3.88

24

0.51

1.11

3.88

27

0.55

1.36

4.50

30

0.62

1.36

4.50

33

0.55

1.50

5.00

36

0.63

1.50

5.00

McQuay IM 777

Operation Guidelines
Figure 29: Wheel-to-Inlet Funnel Relationship40 to 60
Plenum Fans
Cross Section Reference

A
FUNNEL END TO FAN
WHEEL OPENING
EQUALLY
SPACED AROUND
DIAMETER

27

3/8

19.2

22

30

1/2

41.7

55

33

1/2

41.7

55

36

1/2

41.7

55

40

1/2

41.7

55

44

1/2

41.7

55

49

1/2

41.7

55

54

1/2

41.7

55

60

3/4

115

150

Figure 30: Wheel-to-Inlet Funnel RelationshipInline Fans


Overlap

Table 8: Wheel-to-Inlet Funnel RelationshipInline Fans


Wheelfunnel overlap

Table 6: Wheel-to-Inlet Funnel Relationship40 to 60


Plenum Fan
Wheel-Funnel Parameters
Size

40

0.82

2.00

4.88

44

0.91

2.25

5.50

49

1.00

2.50

5.50

54

1.10

2.50

5.50

60

1.23

3.00

5.50

Setscrews on MPQ fan wheels must be installed using a


calibrated torque wrench to the value listed below, 5%.The
fasteners must be periodically checked to satisfy agency
requirements for components on rotating machinery.
Table 7: Setscrew Torque SpecificationsBelt Drive
Plenum Fans Only

Size

Overlap

150

.375

165

.438

182

.562

200

.625

222

.688

245

.750

270

.812

300

.875

330

1.000

365

1.125

402

1.250

445

1.375

Table 9: Bearing Collar and Wheel Hub Set Screw Torque


(All Fans Except Belt Drive Plenum Fans)

Torque (ft.-lb)
Fan Size

Setscrew Size
Aluminum

Steel

Set screw
Diameter (in)

Minimum torque
ft/lbs

kg/m.

13

3/8

19.2

N/A

15

3/8

19.2

N/A

1/4

5.5

.76

1/16

10.5

1.45

16

3/8

19.2

N/A

18

3/8

19.2

N/A

3/8

19.0

2.63

29.0

4.01

20

3/8

19.2

N/A

7/16

22

3/8

19.2

N/A

1/2

42.0

5.81

N/A

5/8

92.0

12.72

24

McQuay IM 777

3/8

19.2

19

Operation Guidelines
Operating Limits
Do not exceed the operating limits in Table 10. A fan wheel
operated beyond the rpm and temperature limits shown can

suffer permanent distortion or fracture. The resulting


unbalance can cause severe unit vibration.

Table 10: Unit Sizes 003 to 035


Fan operating limits
Forward curvedhoused
Diameter

94

97

99

10.62

12.62

15

18

20

22.25

Maximum rpm Class I

N/A

2189

2223

1934

1614

1328

1155

1050

944

24.50
858

Maximum rpm Class Il

2700

2854

2896

2518

2091

1725

1450

1200

1030

910

Diameter

13.22

14.56

16.19

19.69

21.56

24.00

Maximum rpm Class I

3000

3000

2300

2000

1700

1500

Maximum rpm Class Il

4335

3918

3457

2858

2427

2255

Airfoilhoused

Figure 32: Torque for AF Variable Inlet Vanes (inlb)

150

.5

14

AF

750
800
850
900
1000

Fan speed (rpm)

22

3.

1
AF

100
90
80
70
60
50
40
35
30

1500

450
500
550
600
650
700
750
800
850
900
1000

400

350

250

100
90
80

300

150

19

6.

1
AF

4500

00

0.

2
FC

69

9.

1
AF

4000

FC

56

1.

2
AF

3500

.
22

3000

38

.0

4
F2

1500

200

200

Torque (inlb)

250

Torque (inlb)

FC
FC 36.
0
FC 33. 0
00
3
0.
FC
25
27
.6
FC
2
25
.0
0

400
350
300

450
400
350
300
250
200

2500

500

2000

Figure 31: Torque for FC Variable Inlet Vanes (inlb)

Fan speed (rpm)

Table 11: Unit Sizes 040 to 090


Fan operating limits
Forward curvedhoused
Diameter

20

22.38

25

27.62

30.25

33

36

Maximum rpm Class I

1010

930

790

690

650

600

560

Maximum rpm Class Il

1281

1178

1011

910

835

763

715

Airfoilhoused
Diameter

20

22.25

24.5

27

30

33

36.5

Maximum rpm Class I

2077

1875

1691

1479

1328

1209

1073

Maximum rpm Class Il

2703

2413

2199

1928

1730

1579

1401

Figure 33: Torque for FC Variable Inlet Vanes (inlb)

Figure 34: Torque for AF Variable Inlet Vanes (inlb)


2000

300
2

FC

200
Torque (inlb)

5
4.

2
2.

2
FC

1500

.0

0
C2

00

.
18

150

FC

00

.
15

FC

100
90
80
70
60

62

2.

1
FC

Torque (inlb)

250

25

0.

4
AF

1000
900
800
700
600
500
400
350
300
250
200

50

8.

3
AF

.0

3
F3

00

0.

3
AF

00
0
.5
24 2.25
F
A F2
00
0.
A
2
AF

7.

2
AF

150

50

Fan speed (rpm)

20

3000

2500

2000

1500

550
600
650
700
750
800
850
900
1000

2000

1500

500
550
600
650
700
750
800
850
900
1000

450

400

350

100

Fan speed (rpm)

McQuay IM 777

Operation Guidelines
Table 12: Operating LimitsPlenum Fans
Fan operating limits
Plenum fans
Diameter
Class
Maximum rpm

13.5

15

16.5

18.25

20

22.25

24.5

27

30

33

36.5

40.25 44.50
2

49

54.25

60

986

891

75

75

3,909 3,468 2,820 2,930 2,674 2,403 2,183 1,860 1,783 1,620 1,465 1,329 1,202 1,091

Maximum motor HP

7.5

10

15

15

15

20

25

30

40

40

50

60

75

75

Table 13: Operating LimitsInline Fans, Twin Fans


Fan operating limits
Inline fans
Diameter

18.25

20

22.25

24.5

27

30

33

36.5

40.25

44.50

49

54.25

Maximum rpm Class I

2727

2488

2236

2041

1835

1665

1476

1330

1208

1072

973

880

Maximum rpm Class II

3409

3111

2796

2551

2294

2082

1846

1662

1510

1340

1216

1100

Diameter

9x9

10.62

12.62

15

18.12

20

Maximum rpm

2575

2400

2000

1700

1400

1200

Maximum HP

10

15

15

30

40

40

Twin fans

Fan Vibration Levels

Figure 35: Torque Requirements at 100% WOV for


SWSI Plenum Fans with NESTED Inlet Vane
5000
60
0

Each unit as shipped is trim balanced to operate smoothly. To


provide satisfactory operation after shipping and installation,
use the accepted industry guidelines for field balancing fans.
See Table 14.

54
2

4000

49
0

3000

Table 14: Vibration Levels

44
5

Note:
40
2
36
5

1000
900
800
700

Fan speed (rpm)

Vibration

800 or less

5 mils maximum displacement

801 or greater

0.20 in/sec. maximum velocity

Excessive vibration from any cause contributes to premature fan and


motor bearing failure. Monitor overall vibration levels every six
months of operation. An increase in levels is an indication of potential
trouble.

600

Vibration Causes

500

1 Wheel imbalance.

33
0

Torque
(in-lb
)
Torque
(lb./in.)

2000

a Dirt or debris on wheel blades.


300

400

b Loose set screws in wheel hub or bearing-to-shaft.

270

300

c Wheel distorted from overspeed.


2 Bent shaft.

245

200

3 Drive faulty.
a Variable pitch sheavesAxial and radial runout of

Fan Speed (rpm)

3000

2000

1500

700
800
900
1000

600

500

400

300

200

100

flanges; uneven groove spacing; out of balance. Also


similar faults in driven sheave.
b Bad V-belts; lumpy, or mismatched; belt tension too

tight or too loose.


4 Bad bearings, loose bearing hold-down bolts
5 Motor imbalance
6 Fan section not supported evenly on foundation

McQuay IM 777

21

Service and Maintenance


Service and Maintenance

Periodic Maintenance
1 Check all moving parts for wear every six months.
2 Check bearing collar, sheave, and wheel hub setscrews,

Compatibility of grease is critical. Relubricatable bearings are


supplied with grease fittings or zerks for ease of lubrication
with hand or automatic grease guns. Always wipe the fitting
and grease nozzle clean.

sheave capscrews, and bearing hold-down bolts for


tightness every six months.
3 Annually check and snug all electrical connections.

Inspect for signs of water damage such as corrosion and


repair if necessary. Check ground conductor and
connection integrity. Service if needed.

Ball Bearing Lubrication


CAUTION
Bearing overheating potential. Can damage the equipment.
Do not overlubricate bearings. Use only a high grade mineral
grease with a 200F safe operating temperature. See below for
specific recommended lubricants.

Motor Bearings
Supply and return fansSupply and return fan motors
should have grease added after every 2000 hours of operation.
Using the following procedure, relubricate the bearings while
the motor is warm, but not running. Use one of the greases
shown in Table 15.
Table 15: Recommended Lubricants and Amounts for Fan
Motor Bearings
Mfr. Grease

NEMA Size

Amount to Add
(oz.)

Texaco, Polystar
or
Polyrex EM (Exxon Mobile)
or
Rykon Premium #2
or
Penzoil Pen 2 Lube

56 to 140
140
180
210
250
280
320
360
400
440

0.08
0.15
0.19
0.30
0.47
0.61
0.76
0.81
1.25
2.12

1 Remove and clean upper and lower grease plugs.

CAUTION
For safety, stop rotating equipment. Add one half of the
recommended amount shown in Figure 18. Start bearing,
and run for a few minutes. Stop bearing and add the second
half of the recommended amount. A temperature rise,
sometimes 30F (1C), after relubrication is normal. Bearing
should operate at temperature less than 200F (94C) and
should not exceed 225F (107C) for intermittent operation.
For a relubrication schedule, see Table 16. For applications
that are not in the ranges of the table, contact McQuay.

CAUTION
The tables below state general lubrication
recommendations based on our experience and are
intended as suggested or starting points only. For best
results, specific applications should be monitored regularly
and lubrication intervals and amounts adjusted accordingly.
Table 16: Relubrication Intervals
(Use NLGI #2 Lithium or Lithium Complex Grease)
Speed
Temperature
Cleanliness
Relub. intervals
Up to 120F
100 rpm
Clean
6 to 12 months
(50C)
Up to 150F
500 rpm
Clean
2 to 6 months
(65C)
Up to 210F
2 weeks to 2
1000 rpm
Clean
months
(100C)
Over 210F
(100C) to
1500 rpm
Clean
Weekly
250F (120C)
Up to 150F
Above 1500 rpm
Dirty/wet
1 week to 1 month
(65C)
Over 150F
Max catalog rating (65C) to 250F
Dirty/wet
Daily to 2 weeks
(120C)
Above 250F
Contact Browning
(120C)

Table 17: Recommended Lubricants for Fan Shaft Ball


Bearings
Name

Temperature

Base

Thickener

NLGI
grade

Texaco,
Premium RB
Mobile, AW2

30 to 350F
(34 to 177C)
40 to 437F
(40 to 175C)
68 to 356F
(50 to 180C)
60 to 450F
(51 to 232C)

Parafinic
mineral oil
Mineral oil

Lithium

Lithium

Synthetic

Lithium

Synthetic

Lithium

40 to 300F
(40 to 149C)

Mineral oil

Lithium

2 Insert a grease fitting into the upper hole and add clean

grease (Table 15) with a low pressure gun.


3 Run the motor for five minutes before replacing the

plugs.
Note: Specific greasing instructions are located on a tag
attached to the motor. If special lubrication instructions
are on the motor, they supersede all other instructions.

Fan Shaft Bearings


Any good quality lithium or lithium complex base grease,
using mineral oil, conforming to NLGI grade 2 consistency,
and an oil viscosity of 455-1135 SUS at 100F (100-200 cSt at
40C) may be used for relubrication.

22

Mobile, SHC
100
Chevron,
Altiplex
Synthetic
Exxon, ronex
MP
Note:

Temperature ranges over 225F are shown for lubricants only. High
temperature applications are not suitable for standard air handler
components.

McQuay IM 777

Service and Maintenance


2 Verify that both driving and driven sheaves are in
Table 18: Recommended Fan Relubrication Grease Charge
Shaft Size (in)
1/2 to 3/4
7/8 to 1-3/16
1-1/4 to 1-1/2
1-11/16 to 1-15/16
2 to 2-7/16
2-1/2 to 2-15/16
3 to 3-7/16
3-1/2 to 4

OZ.
0.03
0.10
0.15
0.20
0.30
0.50
0.85
1.50

Shaft Size
20 mm
25-30 mm
35-40 mm
45-50 mm
55-60 mm
65-70 mm
75-80 mm
85-105 mm

Grams
0.85
2.84
4.25
5.67
8.51
15.59
24.10
42.53

alignment and that shafts are parallel.


3 Fit internal key D between sheave and shaft and lock
setscrew A securely in place.

Adjusting
1 Loosen setscrews B and C in moving parts of sheave and
pull out external key E. (This key projects a small
amount to provide a grip for removing.)
2 To adjust sheave pitch diameter for desired speed, open

Fan Drive
WARNING
Before servicing fans, lock out and tag out all power to the
unit. Fans or belts can cause severe personal injury or death.

moving parts by half or full turns from closed position.


Do not open more than five full turns for A belts or
six full turns for B belts.
3 Replace external key E and securely tighten setscrews B
over key and setscrews C into keyway in fixed half of the

sheave.
AVERTISSEMENT
Avant de faire le service sur les ventilateurs,couper et
indiquer que le courant est coup. Les ventilateurs ou les
courroies peuvent causer des blessures personnelles graves
ou entraner la mort.

WARNING
Do not open the hinged access door and screw-fastened
access panels while the unit is operating. Moving parts and
strong suction forces can cause severe personal injury or
death.

AVERTISSEMENT

4 Put on belts and adjust belt tension. Do not force belts

over grooves. See Fan Drive Belt Adjustment page 27.


5 Make future adjustments by loosening the belt tension

and increasing or decreasing the pitch diameter of the


sheave by half or full turns as required. Readjust belt
tension before starting drive.
6 To provide the same pitch diameter, adjust both halves of

the two-groove sheaves by the same number of turns


from closed position.
7 Verify that all keys are in place and that all se screws are

tight before starting drive. Check setscrews and belt


tension after 24 hours service.

Ne pas ouvrir les portes daccs charnires et les


panneaux vis lorsque lunit fonctionne. Les pices
mobiles et le niveau de succion peuvent causer des blessures
personnelles graves ou mme entraner la mort.

Figure 36: VP Type Sheave Adjustment

Upon completion of the air balance, replace the variable


pitched motor sheave with a properly sized, fixed sheave. A
matching fixed sheave provides longer belt and bearing life
and minimizes vibration. Initially, it is best to have a variable
pitched motor sheave for the purpose of air balancing. Once
the balance is achieved, fixed sheaves maintain balancing and
alignment more effectively. Replace the adjustable sheaves
with fixed sheaves.

Single Groove
D

C
Key E projects
to provide a grip
for removal.

With the electrical power disconnected, locked and tagged out,


measure the diameter of the V-belt outer surface where it
passes around the sheave (pitch diameter). Calculate fan speed
from the motor nameplate rpm.
Fan rpm = motor rpm

Do not operate
sheeves with flange
projecting beyond
the hub end.
B

Measured diameter at motor sheave


Measured diameter at fan sheave

Two Groove
D

VM and VP Variable Pitch Key Type Sheaves


C

Mounting
1 Mount all sheaves on the motor or driving shaft with the
setscrews A toward the motor.

McQuay IM 777

23

Service and Maintenance


LVP Variable Speed Sheaves

9 Put on belts and adjust belt tension. Do not force belts

over grooves. See Fan Drive Belt Adjustment page 27.


Mounting
1 Slide sheave on motor shaft so that the side of the sheave
with setscrew A is next to the motor when setscrew A is
in the hub or barrel of the sheave.
2 When setscrew A is at an angle in the center flange B,

10 Before starting the drive, ensure that all keys are in place

and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of service.
Adjusting
1 Slack off belt tension if belts have been installed.

mount it away from the motor so that the outer locking


ring and flange can be removed to get to the setscrew.

2 Loosen setscrews D.

3 To remove the flange and locking ring:


a Loosen setscrews D.

3 Loosen but do not remove capscrews E.

b Loosen but do not remove capscrews E.

4 Remove key F.

c Remove key F.

Note: This key projects a small amount to provide a grip for


removing.

Note: This key projects a small amount to provide a grip for


removing.

5 Adjust pitch diameter by opening or closing the movable

flanges by half or full turns.

d Rotate the flange counterclockwise until it disengages

Note: Two-groove sheaves are supplied with both grooves


set at the same pitch diameter.

the threads on the sheave barrel.


4 Verify that the driving and driven sheaves are in

6 To provide the same pitch diameter for satisfactory

alignment and the shafts are parallel. When aligning twogroove sheaves, allow room between the sheave and
motor to access capscrews E.

operation, move both movable flanges the same number


of turns. Do not open sheaves more than five turns for A
belts or six turns for B belts.

5 Insert key C between the sheave and the shaft and tighten
setscrew A securely.

7 Replace key F.
8 Tighten setscrews D and capscrews E.

6 If flange and locking ring have been removed, when

9 If belts have been installed, readjust belt tension. If belts

replacing them make sure that the inner and outer flanges
are open from the closed position by the same amount as
the other flange. Determine this by accurately measuring
the top width of the grooves.

have not been installed, install them and adjust belt


tension. Do not force belts over grooves. See Fan Drive
Belt Adjustment page 27.
10 Before starting the drive, ensure that all keys are in place

7 Insert key F.

and all setscrews and all capscrews are tight. Check and
retighten all screws and retension belts after
approximately 24 hours of operation.

8 Tighten setscrews D and capscrews E.

Figure 37: LVP Type Sheave Adjustment


A

A
E

A
F

D
B

Section A-A

24

Section A-A

McQuay IM 777

Service and Maintenance


MVP Variable Speed Sheaves

into the three holes that are located 120 apart on the
ring.

Mounting
1 Verify both driving and driven sheaves are in alignment
and the shafts are parallel. The centerline of the driving
sheave must be in line with the centerline of the driven
sheave. See Figure 38, page 26.
2 Verify that all setscrews are torqued to the values shown

in Figure 19, page 25 before starting drive. Check


setscrew torque and belt tension after 24 hours of
service.
Adjusting
1 Adjust motor base forward to release belt tension.
Remove the belts for easier adjustment.
2 Loosen, but do not remove both of the locking setscrews
A in the outer locking ring by using a hex key or torque

4 Any pitch diameter can be obtained within the sheave

range. One complete turn of the outer locking ring


changes the pitch diameter 0.233".
5 Do not open sheaves more than the following:
a Do not open B sheaves more than 4 3/4 turns for the A

belts or 6 turns for the B belts.


b Do not open C sheaves more than 9 1/2 turns.
c Do not open 5V sheaves more than 6 turns.
d Do not open 8V sheaves more than 8 turns.
6 Tighten BOTH locking screws A in the outer locking

ring before operating the drive. Use a torque wrench and


tighten to the value shown in Table 19.
7 Replace belts and adjust the motor base to tension the

belts properly. See Fan Drive Belt Adjustment page 27.

wrench with a hex bit.


3 Adjust sheave to desired pitch diameter by turning the

outer locking ring. Use a spanner wrench or drift inserted

8 Do not loosen any screws other than the two locking


screws A in the outer locking ring when adjusting the

sheave pitch. Do not operate the drive until the locking


screws have been set to the torque specifications.
Table 19: Screw Torque Values
Socket head cap screws
Nominal screw size
(dia-thds/in)

1/420NC

Seating torque

Flat head socket


screws

Hollow head set screws only


Lengths equal or greater than dia.

For lengths (L)) less than dia.

Seating torque

Seating torque

Seating torque

Length (L)

Seating torque

(inlbs)

(inlbs)

(inlbs)

(inlbs)

(inlbs)

(inlbs)

(inlbs)

150

12.5

100

87

7.3

3/16

50

5/1611NC

305

25.4

200

165

13.8

1/4

90

3/816NC

545

45.4

350

290

24.2

1/4, 5/16

150, 250

1/213NC

1300

108.3

N/A

620

51.7

N/A

N/A

5/811NC

N/A

N/A

N/A

1225

102.1

N/A

N/A

McQuay IM 777

25

Service and Maintenance


Figure 38: Sheave Adjustment
Must be
parallel

Bearing

Center lines
must coincide

Motor

Adjustable
Sheave
Must be
parallel

Figure 39: Sheave Adjustment


A d ju s ta b le
C e n te r - F la n g e

F ix e d
C e n te r - F la n g e

( 2 ) L o c k in g
S e ts c re w s "A "

F la th e a d S o c k e t S c r e w s
(D o N o t R e m o v e )

S p lit T a p e r
B u s h in g

C a p s c re w s
(D o N o t R e m o v e )

26

S ta tio n a r y
E n d - F la n g e

O u te r
L o c k in g - R in g
In n e r L o c k in g - R in g

( 3 ) H o le s fo r
S p a n n e r W re n c h
o r D r ift

McQuay IM 777

Service and Maintenance


Fan Drive Belt Adjustment
WARNING

General Rules of Tensioning


1 The ideal tension is the lowest tension at which the belt
does not slip under peak load conditions.

Moving belt and fan can cause severe personal injury or death.
During installation and filter maintenance:

Verify that the belt and fan guards on plenum fan units are

2 Check tension frequently during the first 24 to 48 hours of

always in place.

operation.

Lock and tag out fans to prevent accidental start up.

3 Over tensioning shortens belt and bearing life.

Do not enter the filter compartment until the fan is

4 Keep belts free from foreign material that can cause

completely stopped.

slippage.

Use approved equipment for reaching filters located above

5 Inspect V-drive on a periodic basis. Adjust tension if the

normal reach. Do not step on filter frames or unit


components.

belt is slipping. Do not apply belt dressing. This can


damage the belt and cause early failure.

Floor surfaces must be dry and free of oil or grease.

Tension Measurement Procedure


1 Measure the belt span. See Figure 40.

WARNING
Pendant linstallation et o lentretien des filtres, une courroie
en mouvement ou un ventilateur en opration peuvent causer
des blessures graves o mme causer la mort.

2 Place belt tension checker squarely on one belt at the center

of the belt span. Apply force to the checker, perpendicular


to the belt span, until the belt deflection equals belt span
distance divided by 64. Determine the force applied while
in this position.

Sassurer que les gardes de courroie et de ventilateur sont


toujours en place.

Verouiller les dmarreurs des ventilateurs et afficher un avis

3 Compare this force to the values in Table 20.


Figure 40: Drive Belt Adjustment

Deflection =

de mise-en-garde afin de prvenir tout accident ou


dmarrage.

Belt span
64

Attendre que le ventilateur soit compltement arrt avant


dentrer dans lunit.

Utiliser seulement des quipements approuv pour joindre


les bancs de filtres; ne pas mettre soit sur les cadres des
filtres ou mme sur toutes composantes de lunit.

Belt span

La surface des planchers doit tre sec et libre de toute trace


d'huile et o de graisse.

Table 20: Belt Deflection Force (per Browning Specifications)


Number of belts (deflection force lbs)
Cross
section

Small sheave
diameter (in)
0.0 to 3.5

A, AX

B, BX

5V, 5VX

McQuay IM 777

3+

min

max

min

max

min

max

3.0

5.0

2.5

4.0

2.0

3.5

3.6 to 4.4

3.5

5.0

3.0

4.5

2.0

4.0

4.5 +

4.0

5.5

3.0

5.0

2.5

4.5

0.0 to 5.4

5.5

8.0

4.5

7.0

3.5

5.5

5.5 to 7.6

5.5

8.5

4.5

7.5

3.5

5.5

7.7 +

6.5

9.0

5.0

8.0

4.0

6.5

0.0 to 8.5

7.0

11.0

5.5

9.0

4.0

7.0

8.6 TO 12.0

8.5

13.0

6.5

10.5

5.0

8.0

12.1 +

10.0

15.0

7.5

11.5

5.5

9.0

27

Service and Maintenance


Front Load Filter Option

Table 21: Filter Pressure Drops

Front loaded filter options require that the filters be removed


and replaced from inside the unit.
To remove filters, rotate the wire clips. This releases both the
prefilter and the final filter. When installing clean filters, check
to verify the filters are fully seated in the frame (Figure 41).
Figure 41: Frame and Filters with Holding Clips

Bag filtersDriPak 2000


Efficiency

45%

65%

85%

95%

Rated velocity (fpm)

625

500

500

500

Initial pressure drop


Initial pressure drop

.20.26 .2130 .34.48


1.0

1.0

1.0

.50.70
1.0

Cartridge filtersVaricel II MH, 4.25" deep


Efficiency

65%

85%

95%

Efficiency

Rated velocity (fpm)

500

500

500

Rated velocity (fpm)

Initial pressure drop

.43

.61

.70

Initial pressure drop

Final pressure drop

1.5

1.5

1.5

Final pressure drop

Cartridge filtersVaricel SH, 12" deep


Efficiency

70%

Rated velocity (fpm)

500

Initial pressure drop

.39

Final pressure drop

1.2

Pleated panel filters


Type
F in a l
F ilte r
P r e filte r

F ilte r
F ra m e
R o ta te
W ir e C lip s

Perfect pleat

AMAir 300 4"

Efficiency

30%

30%

Rated Velocity (fpm)

500

625

Initial Pressure Drop

.36

.36

Final Pressure Drop

1.0

1.0

5700 filters

Filter Gauges

Efficiency

N/A

Rated velocity (fpm)

500

Filter gauges indicate pressure drop for installed filters.

Initial pressure drop

.25

Table 21 shows the typical filter pressure drop for clean filters
at rated air flow. The tables also show a final pressure drop for
front loaded filters.

Final pressure drop

1.0

Where a single filter gauge is used, the prefilters can be


removed to check the pressure drop of the final filters.

Efficiency

Figure 42: Filter Gauge

Pleated 62 Plus filters


Size

2"

4"

70%

70%

Initial pressure drop

.42

.37

Final pressure drop

1.0

1.0

Coils
1 The coil must be clean to obtain maximum performance.

Check once a year under normal operating conditions


and, if dirty, brush or vacuum clean. Use a chemical coil
cleaner on multiple row coils. Read and follow the
chemical cleaners instructions as some cleaners may
contain harsh chemicals. Take care not to damage fins
while cleaning.
2 Drain pans in any air conditioning unit may have some

moisture. Algae, etc., can grow due to airborne spores


and bacteria. Periodic cleaning is necessary to prevent
this buildup from plugging the drain and causing the
drain pan to overflow. Also, keep the drain pans clean to
prevent the spread of disease. Cleaning should be
performed by qualified personnel.
3 Dirt and lint can clog the condensate drain, especially

overflow.

with dirty filters. Inspect twice a year to help avoid


28

McQuay IM 777

Service and Maintenance


Winterizing Water Coils
Coils can freeze due to air stratification or failure of outdoor
air dampers and/or preheat controls. Do not depend on routine
draining of water cooling coils for winter shutdown as
insurance against freeze-up. Severe coil damage can result.
Drain all coils as thoroughly as possible and then treat in the
following manner.
Fill each coil independently with an antifreeze solution
using a small circulating pump and again thoroughly drain.

If fan replacement is required, the entire fan assembly can be


pulled out the side of the cabinet. The fan assembly includes
the fan housing, the bearing support, and the fan base.
Removing the Fan Assembly
1 Remove the side panels and any intermediate supports
(follow instructions for side panel removal).
2 Once the panels and any intermediate supports are

removed, disconnect the neoprene bulk head seal that is


attached to the fan discharge.

Check freezing point of antifreeze before proceeding to next


coil. Due to a small amount of water always remaining in
each coil, there is a diluting effect. The small amount of
antifreeze solution remaining in the coil must always be
concentrated enough to prevent freeze-up.

3 Remove the four discharge angles that hold the neoprene

Note: Carefully read instructions for mixing antifreeze solution


used. Some products have a higher freezing point in
their natural state when mixed with water. McQuay
International is not responsible for the freezing of
coils.

5 After the fan sled is out, loosen the fan bearings and pull

WARNING
Mold can cause personal injury. Clean drain pan regularly so
mold does not develop.

AVERTISSEMENT
La moisissure prsente un danger respiratoire. Pour viter
la moisissure, nettoyer rgulirement le bassin de drainage.

Removing and Replacing


Components
See Access Doors and Panels page 7 for instructions on
removing panels and opening fan access doors to remove or
replace components.
WARNING
Before removing any component, lock out and tag out all
power to the unit. Fans and belts can cause severe personal
injury or death.

AVERTISSEMENT
Avant denlever toute composante, couper et indiquer que
lalimentation lectrique lunit est coupe. Les
ventilateurs et les courroies peuvent entraner des blessures
personelles graves ou mme la mort.

Removing the Fan Section


The fan shaft, motor, and any drive components can be
removed and replaced through the access door opening. If
required, the side panel can be removed for additional access.

canvas in place around the discharge opening.


4 Disconnect the fan sled from each of the corner mounts

and pull the entire assembly out the side of the unit.
out the shaft.
6 Disconnect the fan housing from the fan sled, and

bearing support by removing the attaching bolts.


7 Replace the new fan, reconnect the shaft and bearings

and put the fan assembly in the cabinet.


8 Replace panels and fasteners.

Removing and Replacing the Coil


Removing Single Coils
Note: Single coils are bolted to the unit on the connection end.
The connection end is held in place with a clamp.
1 Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.


2 Remove all screws and remove the access panel.
3 Remove the screws holding the coil in place.
4 Lift and pull the coil out the side.
Installing Single Coils
1 Slide the coil through the opening in the coil section onto

the bottom coil rests.


2 To prevent any air bypass around the coil, place coils up

against the coil bulkheads. See Single Coil Top


Installation/Removal page 30.
3 Once the coil is in place, fasten the coil to the section.
4 Caulk the seams between the coil casings and bulkheads.
5 If this is an additional coil being installed and not a

replacement, locate the coil supply and return


connections dimensionally. Carefully drill holes in the
end panels of the unit.
6 Remove the brass plugs for the vents and drains on the

connections.
7 Slip the panel over the connections.
8 Replace the brass plugs and panel fasteners.

McQuay IM 777

29

Service and Maintenance


Figure 43: Single Coil Top Installation/Removal
Opposite
connection
end

Connection
end

Coil

Removing Stacked Coils


Note: Top and bottom stacked coils are held together with steel
plate and screws on one side and drain trough and
screws on the other side. Remove the plate and trough
before removing the coils. The coils cannot be removed
attached together.
1 Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.


2 Remove all screws and remove the access panel.
Coil

3 Remove the bolts holding the coil in place and then lift

and pull out the coil from the side.


4 Remove the steel plate and the drain trough that holds

the coils together.


5 Remove the bolts on both ends of the top coil holding it

in place and then lift and slide the coil out.


6 Remove the bolts on both ends of the bottom coil

holding it in place and then lift and slide the coil out.
Installing Stacked Coils
1 Slide the bottom coil through the opening in the coil

section onto the bottom coil rests.


2 Place the coil up against the coil bulkheads to prevent

any air bypass around the coil.


3 Once the coil is in place, bolt the coil to the section.
4 Caulk the mounting surface of the steel plate and install

the plate on the coils.


5 Caulk the mounting surface of the drain trough and

install the drain trough on the coils.


6 Caulk the seams between the coil casings and blockoffs.
7 Connect all piping and install the brass plugs for the
Figure 44: Single Coil Side Installation/Removal
Opposite connection end

Connection end

vents and drains located in the connections.


8 Install the access panel.
Removing and Installing Staggered Coils

Coil

Staggered coils have two banks of coils positioned a few


inches apart in the direction of airflow. Both coils are secured
to the unit on the connection and opposite connection end of
the unit.

Coil

1 Disconnect all piping and remove the brass plugs for the

vents and drains located in the connections.

Coil
Bulkhead

2 To access bolts holding the coils in place, remove the

panels on both the connection and opposite connection


end of the coil section.
3 Each coil is held in place with bolts located in the

corners of the coil side plates. Remove the bolts and then
lift and pull the coil out the side.
4 The bottom coil is fastened to the air block off plate.

Remove the screws attaching this plate to the coil.


Coil
Rests

5 Once the fasteners holding the coil in place are removed,

pull out the coil from either side of the unit.


6 Install the coils in reverse order of removal.

30

McQuay IM 777

Parts
Parts

Replacement Parts
When writing to McQuay for service or replacement parts,
refer to the model number and serial number of the unit
stamped on the serial plate attached to the unit. If replacement
parts are required, mention the date of installation of the unit
and date of failure, along with an explanation of the
malfunctions and a description of the replacement parts
required.

McQuay IM 777

31

Service and Warranty Procedure


Service and Warranty Procedure

Warranty
Consult your local McQuay Representative for warranty
details. Refer to Form 933-43285Y. To find your local
McQuay Representative, go to www.mcquay.com.

Warranty Return Material Procedure


Defective material may not be returned without permission of
authorized factory service personnel of McQuay International
in Minneapolis, Minnesota, (763) 553-5330. A Return
Goods tag must be included with the returned material. Enter
the required information to expedite handling and prompt
issuance of credits. All parts must be returned to the

32

appropriate McQuay facility, designated on the Return


Goods tag. Transportation charges must be prepaid.
The return of the part does not constitute an order for
replacement. Therefor, a purchase order must be entered
through the nearest McQuay representative. The order should
include part number, model number, and serial number of the
unit involved.
Credit will be issued on customer's purchase order following
an inspection of the return part and upon determination that the
failure is due to faulty material or workmanship during the
warranty period.

McQuay IM 777

Check, Test, and Start Procedure Form


Check, Test, and Start Procedure Form

To comply with the terms of McQuay Warranty, complete and return this form within 10
days to McQuay Warranty Department.
Check, test, and start procedure for McQuay Air Handling Units with or without heat recovery.
Job Name:________________________________________ McQuay S.O. No.: _________________ McQuay G.O. No.: _________________
Installation address: __________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Purchasing contractor:________________________________________________________________________________________________
City: ______________________________________________________________________________ State: __________________________
Name of Person doing start-up (print) ___________________________________________________________________________________
Company name _____________________________________________________________________________________
Address ___________________________________________________________________________________________
City/State/Zip_______________________________________________________________________________________
Unit model number: ________________________________________________ Unit serial number: _______________________________
SF VFD model number:_____________________________
RF VFD model number:_____________________________

Serial number: ___________________________________


Serial number: ___________________________________

N/A
N/A

Circle Yes or No. If not applicable to the type of unit, circle N/A.
I. INITIAL CHECK
A. Is any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

B. Are fan drives properly aligned and belts properly adjusted? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

C. Tightened all setscrews on pulleys, bearings and fans? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

D. Have the hold-down bolts been backed off on spring mounted fan isolators? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

E. With power off, do fans turn freely by hand? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

F. Electrical service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

G. Is the main disconnect adequately fused and are fuses installed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

H. Are all electrical power connections tight? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

I. Is the condensate drain trapped?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

J. Fill drain pan. Does water drain freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

K. Is the unit mounted level? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

A. Are blades and seals present?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

B. Do dampers open smoothly and shut tight?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

Yes

No

N/A

Volts __________

Hertz __________

Phase __________

II. FAN DATA


A. Check rotation of supply fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Voltage at supply fan motor:

12 _________ V

C. Supply fan motor amp draw per phase:

23__________V

13 _________ V

L1____________

L2 ___________

L3 ___________

D. Overload amp setting: ______________


E. What is the supply fan rpm? ______________
F. Check rotation of return fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Voltage at return fan motor:

12 _________ V

H. Return fan motor amp draw per phase:

23__________V

13 _________ V

L1____________

L2 ___________

L3 ___________

I. Overload amp setting: ______________


J. What is the return fan rpm? ______________
K. Record supply static pressure at unit discharge: _______ inches of H20
L. Record return static pressure at unit (with outside air dampers closed) _____________ inches of H20
III. DAMPERS

IV. ELECTRIC HEAT


A. Electrical heat service corresponds to unit nameplate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
_________ Volts

_________Hertz

_________Phase

B. Are there any signs of physical damage to the electric heat coils? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

C. Have all electrical terminals been tightened?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

D. Does sequence controller stage contactors properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

E. Electric heater voltage across each phase:

L12_________V

L23 ________ V

L13 _______ V

Stage 3

Stage 4

Stage 5

____________

____________

F. Amp draw across each phase at each heating stage:


Stage 1
Phase L1:

McQuay IM 777

___________

Stage 2
___________

___________

Stage 6
___________

33

Check, Test, and Start Procedure Form


Phase L2:

___________

___________

____________

____________

___________

___________

Phase L3

___________

___________

____________

____________

___________

___________

G. FLA:

L1 ___________

L2 ___________

L3____________

H. Operate electric heat with fans off. Electric heat must cycle OFF on high limit control. . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

B. Drain pan draining okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

Yes

No

N/A

A. Heat wheel rotates freely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

B. Heat wheel VFD operates properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

V. CHILLED WATER COIL

VI. HOT WATER COIL


A. Pressure test okay? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII. HEAT RECOVERY

C. Heat wheel VFD model #_____________________ serial #:_____________________ . . . . . . . . . . . . . . . . . . . . . . .


D. Check for air bypass around heat wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature: ______________________________________________________

N/A

Startup date:____________________________________

RETURN COMPLETED FORM WITHIN 10 DAYS OF START-UP TO:


McQuay International Warranty Department, 13600 Industrial Park Boulevard, Minneapolis, MN 55441
Please list any additional comments that could affect the operation of this unit; e.g., shipping damage, failed components, adverse installation
applications, etc., on a separate sheet and attach to this form.

34

McQuay IM 777

Quality Assurance Survey Report


Quality Assurance Survey Report

Quality Assurance Survey Report


To whom it may concern:
Please review the items below upon receiving and installing our product. Mark N/A on any item that does not apply to the
product.
Job Name: _____________________________________________________

McQuay G.O. no. __________________

Installation Address: _____________________________________________________


City: __________________________________________________________

State: __________________

Purchasing Contractor: __________________________________________________


City:__________________________________________________________

State: __________________

Name of person doing start-up (print): _____________________________________________________


1. Is there any shipping damage visible? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

__ Location on unit _____________________________________________________


2. How would you rate the overall appearance of the product; i.e., paint, fin damage, etc.?
Excellent

Good

Fair

Poor

3. Did all sections of the unit fit together properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

4. Did the cabinet have any air leakage? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Yes

No

N/A

Yes

No

N/A

Location on unit ___________________________________________________________________________


5. Were there any refrigerant leaks? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping

Workmanship

6. Does the refrigerant piping have excessive vibration?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design
Yes

No

N/A

Yes

No

N/A

Yes

No

N/A

Location on unit ___________________________________________________________________________


7. Did all of the electrical controls function at start-up? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comments _______________________________________________________________________________
8. Did the labeling and schematics provide adequate information? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. How would you rate the serviceability of the product?
Excellent

Good

Fair

Poor

Good

Fair

Poor

Fair

Poor

10. How would you rate the overall quality of the product?
Excellent

11. How does the quality of McQuay products rank in relation to competitive products?
Excellent

Good

Comments:
Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed
components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a
separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty
Department with the completed preceding Equipment Warranty Registration Form.

McQuay IM 777

35

McQuay Training and Development

Now that you have made an investment in modern, efficient McQuay equipment, its care should be a high priority.
For training information on all McQuay HVAC products, please visit us at www.mcquay.com and click on training,
or call 540-248-9646 and ask for the Training Department.

Warranty

All McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product
Warranty. Consult your local McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your
local McQuay Representative, go to www.mcquay.com.

This document contains the most current product information as of this printing. For the most up-to-date product
information, please go to www.mcquay.com.

2010 McQuay International www.mcquay.com 800-432-1342

05/10

TAB 4

Installation Manual

SD-IOM-1.0

6-15-02

Single Duct VAV Terminals


Receiving Inspection

Duct Connections

After unpacking the terminal, check it for


shipping damage. If any shipping
damage is found, report it immediately
to the delivering carrier. Store units in a
clean, dry location prior to installation.

Slip each inlet duct over the inlet collar


of the terminal. Fasten and seal the
connection by the method prescribed by
the job specification.

Caution: Do not use the flow sensor,


connecting tubing, or damper shaft
linkage as a handle to lift or move
a s s e m b l y. D a m a g e t o t h e f l o w
sensor or controls may result.

Supporting the Assembly


Many basic single duct terminals are
light enough to be supported by the duct
work itself. Where heavier accessory
modules, such as DDC controls, coils,
attenuators, or multiple outlets are
included, the terminal should be
supported directly. Straps screwed
directly into the side of the terminal,
threaded rod through t h e o p t i o n a l
hanger brackets (see Figure 1), or the
method prescribed for the rectangular
duct on the job specifications may be
used.
Important: If equipped with pneumatic
controls, the terminal must be mounted
right side up. It must be level within
+ or - 10 degrees of horizontal, both
parallel to the air flow and at the right
angle of air flow. The control side of the
terminal is labeled with an arrow
indicating UP. The first letter of the
model number (P) indicates pneumatic
controls. Most electronic units (A-analog
controls and D-digital controls) can be
installed in any orientation. Check with
the local TITUS representative for
verification.

The diameter of the inlet duct "D" in


inches must be equal to the listed size
of the terminal; e.g. a duct that actually
measures 8 inches must be fitted to a
size 8 terminal. The inlet collar of the
terminal is made 1/8 inch smaller than
listed size in order to fit inside the duct
(see Figure 1).
Note: Do not insert duct work inside
the inlet collar of the assembly. Inlet
duct should be installed in accordance
with SMACNA guidelines.

The outlet end of the terminal is


designed for use with slip and drive duct
connections. A rectangular duct the size
of the terminal outlet should be
attached.
If single-point electronic velocity sensor
is used, 3 to 5 inlet duct diameters of
straight duct should be provided at the
terminal inlet; for specific guidelines,
consult the manufacturers installation
material. Sensor(s) may be attached to
the inside of control enclosu r e f o r
protection during shipping. Sensor must
be inserted in inlet duct of terminal
before operation. Remove any
protective plastic devices from tip of
sensor before installation.

2" TYP

Optional
Hanger Bracket
70738001
1 1/2" TYP
1 1/2" TYP
2" TYP

W / ATTENUATOR

1 1/2" TYP
2" TYP

W / ELECTRIC HEAT

1 1/2" TYP
Figure 1. Single Duct Recommended Hanger Bracket Locations

SD-IOM-2.0

Field Wiring
All field wiring must comply with the local codes and
with the National Electrical Code (ANSI/NFPA 70-1981).
Electrical, control and piping diagrams are shown on the
exterior labeling or on the diagram on the inside of
control enclosure cover. All electric heaters if provided
by TITUS are balanced by kW per stage. The installing
electrician should rotate these heater stages by phase
in order to help balance the building electric load.

6-15-02

Replacement Parts
Description

Part Number

Primary Damper Assembly


Size 4-5-6"
Size 7"
Size 8"
Size 9"
Size 10"
Size 12"
Size 14"
Size 16"

31171301
31171302
31171303
31171304
31171305
31171306
31171307
31171308

Damper Shaft Extension


Short Stub all sizes
Long Ext. Sz. 4-6, 14, 16
Long Ext. Sz. 7-12
Shaft Bearing - All

70300301
70300302
70300303
70324901

Important: Units with digital controllers may incorporate


specific communication addresses based on Building
Management Systems Architecture, and original
engineering drawings. Installing the terminal in a
different location than noted on unit label may result in
excessive start-up labor.

Control Tube
Red Stripe 1/4" O.D.
Green Stripe 1/4" O.D.
Red Stripe 3/8" O.D.
Green Stripe 3/8" O.D.
Yellow Stripe 1/4" O.D.
White Stripe 1/4" O.D.
Blue Stripe 1/4" O.D.

61510035
61510234
61510279
61510280
61510260
61510261
61510262

Calibration Instructions

Tees for sensor taps


Plastic 1/4"
Plastic 3/8"

42150011
42150020

Plugs for tees


1/4"
3/8"

42160081
10015601

Control Start-up, Operation


Detailed information regarding power, accessory and
communications connections, start-up and operating
procedures for the controls provided by TITUS are
available from your local TITUS representative. For
specific information on contr ols by other manufacturers,
contact that manufacturers local branch or dealer.

For Pneumatic Controls, see PNEU-IOM: Operations


Manual for Pneumatic Controls.
For Analog Controls: Titus TA1, see ANA-IOM: Analog
Controller Calibration.
For Digital Controls: see control manufacturer's manual

AeroCrossTM Multipoint Velocity Sensors


Size 4"
3151520001
Size 5"
3151520001
Size 6"
3151520002
Size 7"
3151520003
Size 8"
3151520004
Size 9"
3151520005
Size 10"
3151520006
Size 12"
3151520007
Size 14"
3151520008
Size 16"
3151520009
Size 24" x 16"
3151520009

TAB 5

PN 471558
Downblast Centrifugal Roof Exhaust Fans

Installation, Operation and Maintenance Manual


Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
product described. Protect yourself and others by observing all safety information. Failure to comply with instructions
could result in personal injury and/or property damage! Retain instructions for future reference.

Model G
Direct Drive
Model G is a direct drive downblast
centrifugal exhaust fan. These fans
are specifically designed for roof
mounted applications exhausting
relatively clean air. Performance
capabilities range up to 4,300 cfm
(7,305 m3/hr) and up to 1in.wg
(249Pa) of static pressure. The
maximum continuous operating
temperature is 180F (82C).
Gmodels are available in sixteen
sizes with nominal wheel diameter
ranging from 8 to 18 inches
(203to457 mm) (060-180unitsizes). Each fan shall bear
a permanently affixed manufacturers engraved metal
nameplate containing the model number and individual
serial number. All fans are UL/cUL listed Standard 705.

Model GB
Belt Drive
GB Model Fans are belt drive
downblast centrifugal exhaust
fans. These fans are specifically
designed
for
roof
mounted
applications exhausting relatively
clean air. Performance capabilities
range up to 44,700 cfm (75,950
m3/hr) and up to 2.5in.wg (623 Pa)
of static pressure. The maximum
continuous operating temperature
is 180F (82C). GBmodels are
available in twenty sizes with
nominal wheel diameters ranging
from 11 to 54 inches (279 to 1372 mm) (071-540 unit sizes).
Each fan shall bear a permanently affixed manufacturers
nameplate containing the model number and individual
serial number. All fans are UL/cUL listed Standard 705.

General Safety Information


Only qualified personnel should install this fan. Personnel
should have a clear understanding of these instructions
and should be aware of general safety precautions.
Improper installation can result in electric shock, possible
injury due to coming in contact with moving parts, as
well as other potential hazards. Other considerations
may be required if high winds or seismic activity are
present. If more information is needed, contact a licensed
professional engineer before moving forward.

DANGER
Always disconnect, lock and tag power source before
installing or servicing. Failure to disconnect power
source can result in fire, shock or serious injury.
CAUTION
When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
CAUTION

Precaution should be taken in explosive atmospheres.

Model G/GB Centrifugal Roof Exhaust Fans

1. Follow all local electrical and safety codes, as well as


the National Electrical Code (NEC) and the National
Fire Protection Agency (NFPA), where applicable.
Follow the Canadian Electric Code (CEC) in Canada.
2. The rotation of the wheel is critical. It must be free
to rotate without striking or rubbing any stationary
objects.
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than max cataloged fan
RPM. Adjustments to fan speed significantly effects
motor load. If the fan RPM is changed, the motor
current should be checked to make sure it is not
exceeding the motor nameplate amps.
5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open access doors to a duct while the fan is
running.

Receiving
Upon receiving the product check to make sure all items
are accounted for by referencing the bill of lading to
ensure all items were received. Inspect each crate for
shipping damage before accepting delivery. Notify the
carrier if any damage is noticed. The carrier will make
notification on the delivery receipt acknowledging any
damage to the product. All damage should be noted on
all the copies of the bill of lading which is countersigned
by the delivering carrier. A Carrier Inspection Report
should be filled out by the carrier upon arrival and
reported to the Traffic Department. If damaged upon
arrival, file a claim with carrier. Any physical damage
to the unit after acceptance is not the responsibility of
Greenheck Fan Corporation.

Hook With
Safety Latch
(Supplied by others)
(2) Bearing Plate
Lifting Points

Fig. 2

(4) Drive Frame


Lifting Points

Screws

Screws

Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only items
on the bill of lading.

Handling
G Direct Drive
Lift unit on to the roof utilizing hooks under the lip of the
shroud. Evenly space the hooks around the shroud using
a minimum of four lifting straps. Use a spreader bar to
ensure the straps do not come in contact with the unit
(see figure 1).

Fig. 3

1 in.
(44 mm)
Curb Cap

When G/GB unit is on the roof, move fan to desired


location using lifting points and fasten securely through
mounting holes in base. Shims may be necessary
depending upon roofing material thickness.
The motor amperage and voltage ratings must be
checked for compatibility to supply voltage prior to
final electrical connection. For G/GB installations, the
electrical supply should be routed through the conduit
chase located between the curb cap and the bottom of
the motor compartment. Wiring must conform to local
and national codes.

Storage

Spreader Bar

Fans are protected against damage during shipment. If


the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the fan and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.

Lifting
Strap

Indoor

Fig. 1

Hook

GB Belt Drive
When lifting the unit on to the roof, use either the four
lifting points on the drive frame or the two lifting points
on the bearing plate if present (see figure 2 for lifting
points). Access to the drive frame is accomplished by
removing the screws pointed out in figure 3. The cover
can then be removed and placed on a flat surface in an
area protected from strong winds.


Model G/GB Centrifugal Roof Exhaust Fans

The ideal environment for the storage of fans and


accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain or snow. Temperatures should be
evenly maintained between 30 to 110F (-1 to43C)
(wide temperature swings may cause condensation
and sweating of metal parts). All accessories must be
stored indoors in a clean, dry atmosphere.
Remove any accumulations of dirt, water, ice or snow
and wipe dry before moving to indoor storage. To avoid
sweating of metal parts allow cold parts to reach room
temperature. To dry parts and packages use a portable
electric heater to get rid of any moisture buildup. Leave
coverings loose to permit air circulation and to allow for
periodic inspection.

The unit should be stored at least 3 inches (89 mm)


off the floor on wooden blocks covered with moisture
proof paper or polyethylene sheathing. Aisles between
parts and along all walls should be provided to permit air
circulation and space for inspection.

Outdoor
Fans designed for outdoor applications may be stored
outdoors, if absolutely necessary. Roads or aisles for
portable cranes and hauling equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the fan. The fan should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight and space for periodic inspection. To minimize
water accumulation, place all fan parts on blocking
supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Fan wheels should be blocked to prevent spinning
caused by strong winds.

Inspection and Maintenance During


Storage
While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lint-free
cloths. Polish any remaining rust from surface with
crocus cloth or fine emery paper and oil. Do not destroy
the continuity of the surfaces. Thoroughly wipe clean
with Tectyl 506 (Ashland Inc.) or the equivalent. For hard
to reach internal surfaces or for occasional use, consider
using Tectyl 511M Rust Preventive, WD-40 or the
equivalent.

Typical Roof Mounting Installation

1. On the roof surface, cut an appropriate sized hole


and follow manufacturers instructions on curb
installation. Caulk and flash the curb to ensure a
water tight seal.
2. If unit is equipped with a backdraft damper, it should
be installednow.
3. Remove motor cover. Access to the motor
compartment is accomplished by removing the
screws as shown in figure 3.
4. Only on GB Belt Drive fans. On the drive frame use
the lifting lugs to lift and place the unit on top of roof
curb. (Refer to figure 2 on page 2).
5. Secure fan to curb using a minimum of eight lug
screws, metal screws or the suitable fasteners.
Shims may be required depending upon curb
installation and roofing material.
6. Verify power line wiring is de-energized before
connecting fan motor to power source.
7. Connect power supply wiring to the motor as
indicated on the motor nameplate or terminal box
cover. Check the power source for compatiblity with
the requirements of your equipment.
8. Check fan wheel for free rotation, re-center if
necessary.
9. Check all fasteners for tightness.
10. Mount and wire safety disconnect switch under
motor cover. Wire control switches at ground level,
refer to figure 4.
12. Replace motor cover.

Typical Wiring Diagram


MOTOR

MOTOR
SUPPLY VOLTAGE
115/208-230/60/1

J-BOX

Fig. 4

SUPPLY VOLTAGE
208-230/460/60/3
J-BOX

L1
L2

L1
L3

L2

Removing From Storage


As fans are removed from storage to be installed in their
final location, they should be protected and maintained
in a similar fashion until the fan equipment goes into
operation.

Installation
WARNING
Installation, troubleshooting and parts replacement
is to be performed only by qualified personnel.
WARNING
Disconnect power before installing or servicing.


Model G/GB Centrifugal Roof Exhaust Fans

G - Direct Drive

G Direct Drive
Damper

Roof
Opening

*Approx.
Weight

G 060, 065, 070, 075 17 (432)

8 (203)

1012 (267)

18 (8)

G 080, 085, 090, 095 17 (432)

10 (254)

12 2 (318)

26 (12)

G 101, 121

19 (483)

12 (305)

14 2 (368)

43 (20)

G 131,141

22 (559)

16 (406)

18 2 (470)

58 (26)

G 150

26 (660)

16 (406)

18 2 (470)

59 (27)

G 160, 170

30 (762)

18 (457)

20 2 (521)

81 (37)

G 180

30 (762)

18 (457)

20 2 (521)

118 (54)

Model

Curb
Cap

Curb
Cap

Damper

Roof
Opening

*Approx.
Weight

GB 071, 081, 091

19 (483)

12 (305)

14 (368)

58 (26)

GB 101, 101HP

19 (483)

12 (305)

14 (368)

63 (29)

GB 121

19 (483)

12 (305)

14 (368)

66 (30)

GB 131

19 (483)

12 (305)

14 (368)

67 (30)

GB 141, 141HP

22 (559)

16 (406)

18 (470)

83 (38)

GB 161, 161HP

22 (559)

16 (406)

18 (470)

89 (40)

GB 180, 180HP

30 (762)

18 (457)

20 (521)

125 (57)

GB 200, 200HP

30 (762)

18 (457)

20 (521)

138 (63)

GB 220, 240, 220HP

34 (864)

24 (610)

26 (673)

158 (72)

GB 260

40 (1016) 30 (762)

32 (826)

305 (138)

GB 300, 300HP

40 (1016) 30 (762)

32 (826)

320 (145)

GB 330

46 (1168) 36 (914)

38 (978)

385 (175)

GB 360, 360HP

46 (1168) 36 (914)

38 (978)

403 (183)

GB 420

52 (1321) 42 (1067)

44 (1130)

495 (225)

GB 480

52 (1321) 48 (1219)

50 (1283)

623 (283)

GB 500

64 (1626) 54 (1372)

56 (1435)

687 (312)

GB 540

64 (1626) 54 (1372)

56 (1435)

748 (339)

All dimensions are in inches (millimeters). *Approximate weight shown in pounds


(kilograms) is the largest cataloged Open Drip Proof motor.
The roof curb should be 1 in. (38 mm) less than the curb cap to allow for roofing and
flashing.

Disconnect

Screws

in.
Wiring by Others

GB - Belt Drive
Model

Fig. 5 - Typical Roof Mounting Installation

8 or 12 in.
(203 or 305)

(19)

Damper
1 in.
(32)

Recommended Duct
and Damper Size
Recommended Roof
Opening

1 in.
(32)
*Dimensions shown
in inches (mm)

GB Belt Drive
Fig. 6 - Typical Roof Mounting Installation

Disconnect

in
Wiring by Others

8 or 12 in
(203 or 305)

(19)

Damper
1 in
(32)
*Dimensions shown
in inches (mm)

Recommended Duct
and Damper Size

1 in
(32)

Recommended Roof
Opening

Pre-Starting Checks
1. Check all fasteners and set screws for tightness. The
wheel should rotate freely and be aligned as shown
in figure 7 on page 5.
2. Wheel position is preset and the unit is test run at the
factory. Movement may occur during shipment and
realignment may be necessary.
3. Only G unit - Centering height alignment can be
accomplished by loosening the set screws in the
wheel and moving the wheel to the desired position.
4. Only GB unit - Centering can be accomplished by
loosening the bolts holding the drive frame to the
shock mounts and repositioning the drive frame.
5. Only GB unit - Wheel and inlet cone overlap can be
adjusted by loosening the set screws in the wheel
and moving the wheel to the desired position.


Model G/GB Centrifugal Roof Exhaust Fans

6. Only GB unit - Fan RPM should be checked and


verified with a tachometer.
7. Check wheel rotation (viewing from the shaft side)
by momentarily energizing the unit. On a G unit the
rotation should correspond to the rotation decal on
the unit, see figure 8. On a GB unit rotation should
be clockwise as shown in figure 8 and correspond
to rotation decal on the unit. If wheel rotation is
incorrect reverse two of the wiring leads or check
motor wiring for single phase.

Wheel Overlap and Gap Dimensions


Model

G - Overlap in. (mm)

G 060-095

G 101-180

GB 071-161

H - Gap in. (mm)


32 (2)

4 (6)

4 (6)

8 (10)

2 (13)

GB 180-240

GB 260-540

Belts

Do not force belt(s). Forcing the


belt(s) will break the cords and
cause belt failure

Fig. 9

.
10. If adjustments are made, it is very important
to check
the pulleys for proper alignment. Misaligned pulleys
lead to excessive belt wear vibration, noise and
power loss, see figure 10.

Fig. 7

Wheel Rotation
Fig. 10

Counterclockwise
Airflow

11. Belt tension can be adjusted by loosening four


fasteners on the drive frame, see figure 11. The
motor plate slides on the slotted adjusting arms and
drive frame angles in the same manner.

Fasteners
(4) *Fasteners

Fig. 8

Counterclockwise
Airflow
G 141-180

Clockwise
Airflow
G 060-131
All GB Models

Fig. 11

Clockwise
Airflow

WARNING

Correct direction of wheel rotation is critical. Reversed


rotation will result in poor air performance, motor
overloading and possible burnout.

WARNING
The fan has been checked for mechanical noises at the
factory prior to shipment. If mechanical noise should
develop, suggested corrective actions are offered in
the Troubleshooting section.

IMPORTANT
Over tightening will cause excessive bearing wear and
noise. Too little tension will cause slippage at startup
and uneven wear.

Model GB
Pre-Starting Belt Tension Checks
8. Always loosen tension enough to install belts without
stretching, see figure 9.
9. For units with two groove pulleys, adjust so the
tension is equal in both belts.

*Identical fasteners on
opposing side must also be
loosened.

Model G/GB Centrifugal Roof Exhaust Fans

12a. Sizes 071-161: Belts should be tensioned just


enough to prevent slippage at full load.
Note: Belts should have a slight bow on the slack
side while running at full load (see figure 12a).
12b. Sizes 180-540: Belt tension should be adjusted to
allow 164 in. (0.397 mm) of deflection per inch of belt
span. For example, a 15 in. (381 mm) belt span should
have 1564 in. (0.234 mm) (or about 14in. (6mm)) of
deflection with moderate thumb pressure at mid-point
between pulleys (see figure12b).

Deflection

Slack
Side

Fig. 12a

Fig. 12b

13. The adjustable motor pulley is factory set for the


RPM specified. Speed can be increased by closing
or decreased by opening the adjustable motor pulley.

14. Any increase in speed represents a substantial


increase in the horsepower required by the unit.
15. Motor amperage should always be checked to avoid
serious damage to the motor when speed is varied.

Operation: G / GB
1. Before starting up or operating fan, check all
fasteners for tightness. In particular, check the
setscrews in wheel hub.
2. While in the OFF position or before connecting the
fan to power, turn the fan wheel by hand to be sure it
is not striking the venturi or any obstacle.
3. Start the fan and shut it off immediately to check
rotation of the wheel with directional arrow in the
motor compartment.
4. When the fan is started, observe the operation and
check for any unusual noises.
5. With the system in full operation and all ductwork
attached, measure current input to the motor and
compare with the nameplate rating to determine if
the motor is operating under safe load conditions.
6. Keep inlets and approaches to fan clean and free
from obstruction.

IMPORTANT
Adjust (tighten) belt tension after the first 24-48hours
of operation.

Inspection
Inspection of the fan should be conducted at the first
30minute and 24 hour intervals of satisfactory operation.

30 Minute Interval
Inspect bolts, setscrews and motor mounting bolts.
Adjust and tighten as necessary.

24 Hour Interval
Check all internal components. On GB unit only, inspect
belt alignment and tension. Adjust and tighten as
necessary.

Maintenance: G / GB
Installation and maintenance are to be performed only
by qualified personnel who are familiar with local codes
and regulations and who are experienced with this type
of equipment.
Motor maintenance is generally limited to cleaning and
lubrication (where applicable). Cleaning should be limited
to exterior surfaces only. Removing dust buildup on
motor housing ensures proper motor cooling.

WARNING
Always disconnect, lock and tag power source before
servicing. Failure to disconnect power source can
result in fire, shock or serious injury.

Model G/GB Centrifugal Roof Exhaust Fans

Greasing of motors is only intended when fittings are


provided. Many fractional horsepower motors are
permanently lubricated and should not be lubricated
after installation. Motors supplied with grease fittings
should be greased in accordance with manufacturers
recommendations. Where motor temperatures do not
exceed 104F (40C), the grease should be replaced after
2,000 hours of running time as a general rule.
Wheels require very little attention when moving clean
air. Occasionally, oil and dust may accumulate causing
imbalance. When this occurs the wheel and housing
should be cleaned to ensure smooth and safe operation.
All fasteners should be checked for tightness each time
maintenance checks are performed prior to restarting
unit.
A proper maintenance program will help these units
deliver years of dependable service.

CAUTION
Uneven cleaning of the wheel will produce an out of
balance condition that will cause vibration in the fan.

WARNING
This unit should be made non-functional when cleaning
the wheel or housing (fuses removed, disconnect
locked off).

Belt/Bearing Maintenance GB Unit


1. Belts tend to stretch after a period of time. They
should be checked periodically for wear and
tightness. When replacing belts, use the same type
as supplied with the unit.
2. Matched belts should always be used on units with
multi-groove pulleys.
3. For belt replacement, loosen the tensioning device
enough to allow removal of the belt by hand.
4. Once installed, adjust belts as shown in PreStarting
Checks.
5. Shaft bearings can be classified in two groups:
relubricating and non-relubricating. All
nonrelubricating bearings on standard model GB
fans are factory lubricated and require no further
lubrication under normal use (between -20 to 180F
(-29 to 82C) in a relatively clean environment).
6. On GB belt driven fans, the standard cast pillow
block bearings are factory lubricated and are
provided with external grease fittings. Annual
lubrication is recommended, or more frequently if
needed (see Table2 on page 7). Do not over-grease.
Use only one or two shots of lubricant with a hand
gun. Maximum hand gun rating is 40 psi. Rotate
bearings during lubrication where good safety
practice permits. Caution should be employed to
prevent over packing or contamination.
7. Grease fittings should be wiped clean. The unit
should be in operation while lubricating. Extreme
care should be used around moving parts.

8. Grease should be pumped in very slowly until a slight


bead forms around the seal. A high grade lithium
base grease should be used.
9. To ensure tightness, check pulley setscrews. Proper
keys must be in keyways.
10. Fan RPM should not be readjusted. Only use pulleys
of identical size and type when replacing pulleys.
11. During the first few months of operation check
bearing set screws periodically to ensure tightness.
12. If unit is to be left idle for an extended period,
remove belts and store in a cool, dry place to avoid
premature belt failure.

Recommended Relubrication Frequency in


Months
NOTE: If unusual environment conditions exist (extreme
temperature, moisture or contaminants) more frequent
lubrication is required.
A good quality lithium base grease, conforming to NLGI
Grade 2 consistency, such as those listed here may be
used.

Table 3: Grease Manufacturers


Manufacturer

Grease (NLGI #2)

U.S. Electric Motors

Grease No. 83343

Chevron U.S.A. Inc

Chevron SRI Grease #2


Mobilith

Mobil Oil Corporation

Mobil 532
Premium BRB #2

Texaco, Inc.

Texaco Multifak #2

Amoco Oil Co.

Rykon Premium #2

Exxon

Unirex N2

Shell

B Shell Alvania #2

Table 2: Suggested Fan Bearing Greasing Intervals


Interval
(months)

Type of Service

1 to 3

Heavy duty in dirty, dusty locations; high ambient


temperatures; moisture laden atmosphere;
vibration.

3 to 6

12 to 24 hours per day, heavy duty, or if moisture


is present

6 to 12

8 to 16 hours per day in clean, relatively dry


atmosphere

12 to 18

Infrequent operation or light duty in clean


atmosphere

Poor

Poor

Good

Fan Inlet Connections

In order to assure proper fan performance, caution must be exercised in fan placement and connection to the
ventilation system. Obstructions, transitions, poorly designed elbows, improperly selected dampers, etc, can cause
reduced performance, excessive noise and increased mechanical stress. For performance to be as published, the
system must provide uniform and stable airflow into the fan.
Good

Poor

Poor

Dampers must open


fully. Use motorized
dampers in low airflow
applications to reduce
losses.

Avoid sharp turns or


entrance conditions
which cause uneven
flow. Good
Use turning vanes
in elbows to reduce
adverse effects.

Model G/GB Centrifugal Roof Exhaust Fans

Good

Provide uniform
airflow at fan inlet
to assure optimum
performance.

Provide uniform airflow at fan inlet


and through the damper to assure
optimum performance. The curb cap
should be three wheel diameters
from the radius. Use turning vanes in
duct when possible.

Troubleshooting
WARNING: Before taking any corrective action, make certain unit is not capable of operation during repairs.

PROBLEM

EXCESSIVE NOISE /
VIBRATION

HIGH HORSEPOWER

FAN DOESNT OPERATE

MOTOR OVERLOADS /
OVERHEATS

REDUCED AIRFLOW

CAUSE

CORRECTIVE ACTION

Wheel rubbing inlet

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars
on shaft.

V-belt drive

Tighten pulleys on motor/fan shaft. Adjust belt tension. Align pulleys


properly, see page 5/figure 9-10. Replace worn belts or pulleys.

Bearings

Replace defective bearing(s). Lubricate bearings. Tighten collars and


fasteners.

Wheel unbalance

Clean all dirt off wheel. Check wheel balance, rebalance in place if
necessary.

Bad bearings

Replace.

Belts too tight or too loose

Adjust tension, see figure 12a-b.

Wheel improperly aligned and rubbing

Center wheel on inlet, see figure 7.

Loose drive or motor pulleys

Align and tighten. See Pre-Starting Checks, see page 5-6.

Foreign objects in wheel or housing

Remove objects, check for damage or unbalance.

Fan base not securely anchored

Secure properly.

Motor hood loose and rattling

Tighten acorn nuts securing motor hood.

Defective or loose motor bearings

Replace motor with same frame size, RPM-HP

Fan

Check rotation of wheel, see figure 8. Reduce fan speed.

Duct system

Resize ductwork. Check proper operation of face and bypass


dampers. Check filters and access doors.

Electrical supply

Check fuses/circuit breakers. Check for switches off. Check for


correct supply voltage.

Drive

Check for broken belts. Tighten loose pulleys.

Motor

Assure motor is correct horsepower and not tripping overload


protector.

Lubrication

Check for excessive or insufficient grease in the bearing.

Mechanical

Replace damaged bearing. Relieve excessive


belt tension. Align bearings. Check for bent shaft.

Belt slippage

Adjust tension or replace bad belts, see page 5-6.

Over/Under line voltage

Contact power company.

Incorrect wheel rotation

Check motor wiring, see figure 4.

Wheel RPM too high

Check drives or slow down fan by opening variable pitch pulley on


motor shaft.

Undersized motor

Check motor ratings with catalog speed and air capacity chart.

Motor wired incorrectly

Check motor wiring to wiring diagram located on fan motor.

System resistance too high

Check system: Proper operation of backdraft or control dampers,


obstruction in ductwork, clean dirty filters.

Unit running backwards

Correct as shown in figure 8.

Excessive dirt buildup on wheels

Clean wheel.

Improper wheel alignment

Center wheel on inlets, see Pre-Starting checks and figure 7.

Dampers closed

Inspect and repair.

Blocked duct/clogged filter

Clean or replace.

Belt slippage

Replace and adjust tension.

Speed to slow

Check for correct drives.

Model G/GB Centrifugal Roof Exhaust Fans

Maintenance Documentation
Job Information
Job Name:

Service Organization:

Address:

Address:

City:

City:

State:

Zip:

State:

Zip:

Phone:

Phone:

Contact Person:

Work Done By:

Nameplate Information

Field Start-Up Documentation

Model:

Actual Voltage:

Volts:

Hertz:

Phase:

Actual Phase:

Amps:

Mark:

Actual Amperage:

Supply hp:

Exhaust hp:

Blower Rotation:

Serial Number:

Hertz:

Air Volume:

Model Voltage:

Design cfm:
Actual cfm:

Motor Amperage:

Level of fan (L or H):

Fan RPM:

Fan RPM Range (min.)

(max.)

Maintenance Log
Date

Time

Model G/GB Centrifugal Roof Exhaust Fans

Notes

Parts List
NOTE
Each fan bears a manufacturers nameplate with model number and serial number embossed. This information will assist
the local Greenheck representative and the factory in providing service and replacement parts. Before taking any corrective
action, make certain unit is not capable of operation during repairs.

CAUTION
A fan manufactured with an explosion resistant motor does not certify the entire unit to be explosion proof.

G Direct Drive Centrifugal Roof Exhaust Fan

Motor Cover

Motor
Shock Mounts
Shroud
Birdguard

Wheel

Curb Cap/Venturi

10 Model G/GB Centrifugal Roof Exhaust Fans

Hood Clip

Shroud Brace
Vertical Support

Lower Windband

GB Belt Drive Centrifugal Roof Exhaust Fan

Motor Cover
Belt
Shaft Pulley
Motor Pulley
Drive Frame
Assembly
Bearings
Shock Mounts

Motor

Fan Shaft

Shroud
Wheel

Conduit Chase

Birdguard
Shroud Brace
Windband

Vertical Support
Curb Cap/Venturi

11 Model G/GB Centrifugal Roof Exhaust Fans

Roof Curb Installation

Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of three years
from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our
option when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a
period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned
to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Greenheck Catalog G/GB provides additional information
describing the equipment, fan performance, available accessories,
and specification data.
AMCA Publication 410-96, Safety Practices for Users and Installers of
Industrial and Commercial Fans, provides additional safety information.
This publication can be obtained from AMCA International, Inc. at:
www.amca.org.
Contact Greenheck Fan Corporation:
Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com

12 471558 Model G/GB IOM, Rev. 1, March 2008

Copyright 2008 Greenheck Fan Corp.

Part #459968
Tubular Centrifugal & Mixed Flow

Installation, Operation and Maintenance Manual


Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
product described. Protect yourself and others by observing all safety information. Failure to comply with instructions
could result in personal injury and/or property damage! Retain instructions for future reference.

Model TCF
Tubular Centrifugal Inline Fan

Models QEI and QEID


Mixed Flow Inline Fan

General Safety Information


Only qualified personnel should install this fan.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards.
Other considerations may be required if high winds
or seismic activity are present. If more information
is needed, contact a licensed professional engineer
before moving forward.
DANGER
Always disconnect power before working on or near
a fan. Lock and tag the disconnect switch or breaker
to prevent accidental power up.
CAUTION
When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
CAUTION
Precaution should be taken in explosive
atmospheres.

Model TCF and Models QEI/QEID Centrifugal

1. Follow all local electrical and safety codes, as


well as the National Electrical Code (NEC) and the
National Fire Protection Agency (NFPA), where
applicable. Follow the Canadian Electric Code
(CEC) in Canada.
2. The rotation of the wheel is critical. It must be free
to rotate without striking or rubbing any stationary
objects.
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than max cataloged
fan rpm. Adjustments to fan speed significantly
effects motor load. If the fan RPM is changed, the
motor current should be checked to make sure it is
not exceeding the motor nameplate amps.
5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open access doors to a duct while the fan is
running.

Receiving
Upon receiving the product check to make sure all
items are accounted for by referencing the bill of
lading to ensure all items were received. Inspect
each crate for shipping damage before accepting
delivery. Notify the carrier if any damage is noticed.
The carrier will make notification on the delivery
receipt acknowledging any damage to the product.
All damage should be noted on all the copies of the
bill of lading which is countersigned by the delivering
carrier. A Carrier Inspection Report should be filled out
by the carrier upon arrival and the Traffic Department.
If damaged upon arrival, file claim with carrier. Any
physical damage to the unit after acceptance is not
the responsibility of Greenheck Fan Corporation.

Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing report shortages to your local representative
to arrange for obtaining missing parts. Sometimes it
is not possible that all items for the unit be shipped
together due to availability of transportation and truck
space. Confirmation of shipment(s) must be limited to
only items on the bill of lading.

Handling
Fans are to be rigged and moved by the lifting
brackets provided or by the skid when a forklift is
used. Location of brackets varies by model and size.
Handle in such a manner as to keep from scratching
or chipping the coating. Damaged finish may reduce
the ability of the fan to resist corrosion.
Fans should never be lifted by the shaft, fan housing,
motor, belt guard, windband or accessories.

Storage
Fans are protected against damage during shipment.
If the unit cannot be installed and operated
immediately, precautions need to be taken to prevent
deterioration of the unit during storage. The user
assumes responsibility of the fan and accessories
while in storage. The manufacturer will not be
responsible for damage during storage. The following
suggestions are provided solely as a convenience to
the user.

INDOOR
The ideal environment for the storage of fans and
accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain, or snow. Temperatures should
be evenly maintained between 30F (-1C) and
110F (43C) (wide temperature swings may cause
condensation and sweating of metal parts). All
accessories must be stored indoors in a clean, dry
atmosphere.

Model TCF and Models QEI/QEID Centrifugal

Remove any accumulations of dirt, water, ice or snow


and wipe dry before moving to indoor storage. To
avoid sweating of metal parts allow cold parts to
reach room temperature. To dry parts and packages
use a portable electric heater to get rid of any
moisture build up. Leave coverings loose to permit air
circulation and to allow for periodic inspection.
The unit should be stored at least 3 inches (89 mm)
off the floor on wooden blocks covered with moisture
proof paper or polyethylene sheathing. Aisles between
parts and along all walls should be provided to permit
air circulation and space for inspection.

OUTDOOR
Roads or aisles for portable cranes and hauling
equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the fan. The fan should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To
minimize water accumulation, place all fan parts on
blocking supports so that rain water will run off.
The use of a tarp to cover the unit will aid in keeping it
clean and dry. Avoid using a black plastic tarp as it will
promote condensation.
Fan wheels should be blocked to prevent spinning
caused by strong winds.

Inspection and Maintenance during


Storage
While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. If paint
deterioration begins, consideration should be given
to touch-up or repainting. Fans with special coatings
may require special techniques for touch-up or repair.
Machined parts coated with rust preventive should
be restored to good condition promptly if signs of
rust occur. Immediately remove the original rust
preventive coating with petroleum solvent and clean
with lint-free cloths. Polish any remaining rust from
surface with crocus cloth or fine emery paper and oil.
Do not destroy the continuity of the surfaces. Wipe
clean thoroughly with Tectyl 506 (Ashland Inc.) or
the equivalent. For hard to reach internal surfaces or
for occasional use, consider using Tectyl 511M Rust
Preventive or WD-40 or the equivalent.

REMOVING FROM STORAGE

QEI/QEID Radial Gap

As fans are removed from storage to be installed


in their final location, they should be protected and
maintained in a similar fashion, until the fan equipment
goes into operation.

Adjust inlet cone position such that the radial gap


between the wheel cone and inlet cone is evenly
distributed around the wheel.

Prior to fully assembling and installing the fan and


system components, inspect the fan assembly to
make sure it is in working order.

If necessary, adjust wheel position by loosening the


wheel hub from the fan shaft so that a straight edge
held tight to the wheel cone just touches the inlet
cone. Refer to drawing below.

1. Check all fasteners, set screws, wheel, bearings,


drive, motor base and accessories for tightness.

QEI/QEID Alignment

Straight Edge

2. Rotate the fan wheel by hand and assure no parts


are rubbing. Access to the wheel is obtained
through an access panel located on the side of the
fan housing.

Wheel
Cone

3. Ensure proper wheel settings for radial gap and


alignment. See below.

1 Fan
Wheel
Dia.

Radial Gap, Overlap & Alignment


Efficient fan performance can be maintained by having
the correct radial gap, overlap and alignment. These
items should be checked before start-up and after the
fan has been in operation for 24 hours.

TCF Radial Gap


Radial gap is adjusted by loosening the inlet
cone bolts and centering the cone on the wheel.
If additional adjustment is required to maintain a
constant radial gap, loosening the bearing bolts and
centering wheel is acceptable
Overlap
as a secondary option.

TCF Overlap
Overlap is adjusted by
loosening the wheel hub from
the shaft and moving the
wheel to the desired position
along the shaft. The chart
shows the proper distance
between the wheel and
Radial
the inlet cone.
Gap
TCF Size
18
20
22
24
27
30
33
36
40
44
49
54
60
66
73

Dimension A (in.)
6 8
7
71316
858
9716
10916
11716
1234
14316
15916
1718
181316
201516
2278
2512
3

8
1316
1316
14
14
38
38
38
38
38
12
12
12
12
12
1

Poor

Radial
Gap
Inlet Cone

Installation
Length of
Installations with poor inlet or discharge
Straight Duct
configurations may result in reduced fan performance.

Ducted Installations
Inlet Duct Turns Installation of a duct turn or elbow
too close to the fan inlet reduces fan performance.
Restricted or unstable flow at the fan Good
inlet can cause
pre-rotation of incoming air or uneven loading of the
fan wheel, yielding large system losses and increased
sound levels. To achieve full fan performance, there
should be at least one fan wheel diameter between
the turn or elbow and the fan inlet.
Good

Poor

1 Fan
Wheel
Dia.

Turning
Vanes

Dimension A (mm)
86
178
198
219
240
268
291
324
360
395
435
478
532
581
648

3
5
5
6
6
10
10
10
1 Fan
Wheel
Dia.
10
10
13
13
13
13
13

Discharge Duct
Turns Fan performance
is reduced
Poor
Good
Poor
when duct turns are made immediately
off the fan
discharge. To achieve cataloged fan performance
there should be at least three equivalent duct
1 straight
Fan
diameters ofWheel
ductwork between the fan
Dia.
Poor
discharge and any duct turns.
Poor
Length of
Straight Duct

Good
Length of
Straight Duct

Good
Models TCF and Model QEI/QEID Centrifugal

Non-Ducted Installation

1 Fan
Wheel

Inlet Clearance Installation of a fan with an openDia.


inlet too close to a wall or bulkhead will cause
reduced fan performance.
It is desirable to have a
1 Fan
minimum of one fan wheel
Wheel
Dia.
diameter between the fan
inlet and the wall.
Free Discharge Free
or abrupt discharge
into a plenum results
in a reduction in fan
performance. The effect
of discharge static regain
is not realized, and
performance is reduced.

Unit Start-Up
Poor
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
Length of

Straight Duct
WARNING

Disconnect and secure to the Off position all


electrical power to the fan prior to inspection
or servicing. Failure to comply with this safety
Length of
precaution could result
in Duct
serious injury or death.
Straight

Duct Connections
It is highly recommended to use a flexible sleeve
connection instead of a rigid duct connection. This will
reduce vibration transmission through the ductwork.
Slip-Fit End Connection (QEI/QEID)
Directly attach the flexible sleeve to the duct and fan.
1 Fan
No additional parts are required.
Wheel
Dia.

Flexible Sleeve
Flexible Sleeve

Fan

Duct
Turning
Vanes

Fan

Duct

1 Fan
Wheel
Dia.

Flanged End Connection (TCF/QEI/QEID)


Good
Optional companion flanges Turning
are bolted to the fan to
Vanes
Flexible Sleeve
provide a slip-fit connection
for a flexible sleeve.
Flexible Sleeve

Good
Fan

Duct

Fan

Duct

1. Disconnect
and lock-out all power switches to
Good
fan.
2. Check all fasteners, set screws and locking
collars on the fan, wheel, bearings, drive, motor
base and accessories for tightness.
Good
3. Rotate
the fan wheel by hand and assure no parts
are rubbing.
4. Check for bearing alignment and lubrication.
5. Check the V-belt drive for proper alignment and
tension.
6. Check all guarding (if supplied) to ensure that it is
securely attached and not interfering with rotating
parts.
7. Check operation of variable inlet vanes or
discharge dampers (if supplied) for freedom of
movement.
8. Check all electrical connections for proper
attachment.
Poor
9. Check housing and ductwork, if accessible,
for obstructions and foreign material that may
damage the fan wheel.
10. Check for proper wheel rotation by momentarily
energizing
the fan. Rotation should correspond
Poor
to the rotation decal affixed to the unit (CCW
rotation is correct as viewed from the fan inlet).

Companion Flange
Companion Flange

Note: Flexible sleeve & attachment hardware not provided.


Mixed Flow

Centrifugal Airfoil

NOTE: One of the most frequently encountered


problems with centrifugal fans is motors which are
wired to run in the wrong direction. This is especially
true with 3-phase installations where the motor will
run in either direction, depending on how it has
been wired. To reverse rotation of a 3-phase motor,
interchange any two of the three electrical leads.
Single phase motors can be reversed by changing
internal connections as described on the motor label
or wiring diagram.

Model TCF and Models QEI/QEID Centrifugal

11. If the fan has inlet vanes, they should be partially


closed to reduce power requirements.
12. Fans with multi-speed motors should be checked
on low speed during initial start-up.
13. Ensure proper wheel location for radial gap,
overlap and alignment (see Radial Gap, Overlap
& Alignment section on page 3).
14. Grease may be forced out of the bearing seals
during initial start-up. This is a normal selfpurging feature of the bearing.
15. Check for unusual noise, vibration or overheating
of bearings. Refer to the Troubleshooting section
of this manual if a problem develops.

Vibration
Excessive vibration is the most frequent problem
experienced during initial start-up. Left unchecked,
excessive vibration can cause a multitude of
problems, including structural and/or component
failure.
The most common sources of vibration are:
Wheel unbalance
Drive pulley misalignment
Incorrect belt tension
Bearing misalignment
Mechanical looseness
Faulty belts
Drive component unbalance
Poor inlet/outlet conditions
Foundation stiffness
Many of these conditions can be discovered by careful
observation. Refer to the Troubleshooting section
of this manual for corrective actions. If observation
cannot locate the source of vibration, a qualified
technician using vibration analysis equipment should
be consulted. If the problem is wheel unbalance,
inplace balancing can be done providing there is
access to the fan wheel. Any correction weights
added to the wheel should be welded to either the
wheel back (single-plane balance) or to the wheel
back and wheel cone (two-plane balance).

Maintenance
WARNING
Disconnect and secure to the Off position all
electrical power to the fan prior to inspection
or servicing. Failure to comply with this safety
precaution could result in serious injury or death.
Once the unit has been put into operation, a routine
maintenance schedule should be set up to accomplish
the following:
1. Lubrication of bearings and motor.
2. Variable inlet vanes should be checked for freedom
of operation and wear.
3. Wheel, housing, bolts and set screws on the entire
fan should be checked for tightness.

4. Any dirt accumulation on the wheel or in the


housing should be removed to prevent unbalance
and possible damage.
5. Isolation bases should be checked for freedom
of movement and the bolts for tightness. Springs
should be checked for breaks and fatigue. Rubber
isolators should be checked for deterioration.
6. Inspect fan impeller and housing looking for
fatigue, corrosion or wear.
WARNING
Changing the belts or drives can significantly
increase the amp draw of the motor. If changes
are made to the drives or belts, the amps must be
checked to assure no overamping.

V-Belt Drives
V-belt drives must be checked on a regular basis
for wear, tension, alignment and dirt accumulation.
Premature or frequent belt failures can be caused by
improper belt tension (either too loose or too tight)
or misaligned sheaves. Abnormally high belt tension
or drive misalignment will cause excessive bearing
loads and may result in failure of the fan and/or motor
bearings. Conversely, loose belts will cause squealing
on start-up, excessive belt flutter, slippage and
overheated sheaves. Either excessively loose or tight
belts may cause fan vibration.
When replacing V-belts on multiple groove drives,
all belts should be changed to provide uniform drive
loading. Do not pry belts on or off the sheave. Loosen
belt tension until belts can be removed by simply
lifting the belts off the sheaves. After replacing belts,
ensure that slack in each belt is on the same side of
the drive. Belt dressing should never be used.
Do not install new belts on worn sheaves. If the
sheaves have grooves worn in them, they must be
replaced before new belts are installed.
The proper tension for operating a V-belt drive is
the lowest tension at which the belts will not slip at
peak load conditions. Belts are adjusted by raising or
lowering the motor pivot plate. For initial tensioning,
the proper belt deflection half-way between sheave
centers is 1/64 of the belt span. For example, if the
belt span is 64 inches, the belt deflection should be
1 inch using moderate thumb pressure at mid-point
of the drive. Check belt tension two times during
the first 24 hours of operation and periodically
thereafter.
Deflection = Belt Span
64

Belt Span

Models TCF and Model QEI/QEID Centrifugal

V-Belt Replacement

Fan Bearing Lubrication

The V-belt drive components, when supplied by


Greenheck Fan Corporation, have been carefully
selected for this units specific operating condition.
Changing V-belt drive components could result
in unsafe operating conditions which may cause
personal injury or failure of fan components.

The bearings for Greenheck fans are carefully


selected to match the maximum load and operating
conditions of the specific class, arrangement and
fan size. The instructions provided in this manual
and those provided by the bearing manufacturer will
minimize any bearing problems. Bearings are the
most critical moving part of the fan. Therefore, special
care is required when mounting them on the unit and
maintaining them.

1. Remove the protective coating from the end of the


fan shaft using mineral spirits or another similar
solvent. Check to ensure that the shaft is free of
nicks and burrs.
2. Slide sheaves on shafts. Do not drive sheaves on
as this may result in bearing damage.
3. Align fan and motor sheaves
with a straight-edge or string
and tighten.
4. Place belts over sheaves. Do
not pry or force belts, as this
could result in damage to the
cords in the belts.
5. Adjust the tension until the
Aligning sheaves
belts appear snug. Run the
with a straight edge
unit for a few minutes (refer to
unit start-up section) and allow the belts to set
properly.
6. With the fan off, adjust the belt tension by moving
the motor pivot plate. (Belts are adjusted by
raising or lowering the motor pivot plate). When in
operation, the tight side of the belts should be in
a straight line from sheave to sheave with a slight
bow on the slack side.
FAN

MOTOR

FAN

Motors
Motor maintenance is generally limited to cleaning
and lubrication. Cleaning should be limited to exterior
surfaces only. Removing dust and grease build-up on
the motor housing assists proper motor cooling.
CAUTION
Do not allow water or solvents to enter the motor or
bearings. Under no circumstances should motors or
bearings be sprayed with steam, water or solvents.
Greasing of motor bearings is only required when
fittings are provided. Many fractional motors are
permanently lubricated and require no further
lubrication. Motors supplied with grease fittings
should be greased in accordance with the
manufacturers recommendations. When motor
temperature does not exceed 104F (40C), the grease
should be replaced after 2000 hours of running time.

Model TCF and Models QEI/QEID Centrifugal

MOTOR

Refer to the following chart and the manufacturers


instructions for grease types and intervals for various
operating conditions. Never mix greases made with
different bases. This will cause a breakdown of the
grease and possible failure of the bearing.
Recommended Fan Bearing Lubrication Schedule (in Months*)
Fan
RPM

Bearing Bore
15
2 - 1 1 8 - 1 2 1 8 - 178 -12316
16

2716
-3

3316
- 312

31516
- 412

To 250

500

750

1000

1250

0.5

0.5

1500

0.5

0.5

0.25

2000

0.5

0.25

0.25

0.25

2500

0.5

0.5

0.25

0.25

0.25

3000

0.5

0.25

0.25

0.25

*Suggested initial greasing interval is based on 12 hour per


day operation and 150 F. maximum housing temperature.
For continuous (24 hour) operation, decrease greasing
interval by 50%.
If possible, relubricate with grease while in operation
without endangering personnel.
For ball bearings (operating) relubricate until clean
grease is seen purging at the seals. Be careful not to
unseat the seal by over lubricating.
For ball bearings (idle) add 1-2 shots of grease up to 2
in. bore sizes, and 4-5 shots of grease above 2in. bore
sizes with hand grease gun.
For roller bearings, relubricate with 4 shots of grease up
to 2 in. bore size, 8 shots for 2-5 in. bore size, and 16
shots above 5 in. bore size with hand grease gun.
Adjust lubrication frequency based on condition of
purged grease.
A high quality lithium base grease conforming to NLGI
Grade 2 consistency, such as those listed below, should
be used.
Mobilith SHC 220
Texaco Multifak AFB2
Mobilith AW2
Texaco Premium RB
Shell Alvania #2
Exxon Unirex N2

WARNING
Lubricate bearings prior to periods of extended
shutdowns or storage and rotate shaft monthly to
aid in preventing corrosion. If the fan is stored more
than three months, the bearings should be purged
with new grease prior to start-up.

Fan Bearing Replacement


Replacement of bearings requires disassembly of internal components. For this procedure access must be
available to both the inlet and outlet ends. The following procedure assumes belts have already been loosened
and removed. (Belts are removed by adjusting the motor pivot plate).
Reinstall components in reverse order of removal. Reference the Radial Gap, Overlap & Alignment section to
ensure proper wheel installation.

Model TCF

Model QEI

1. Remove cover plate from drive chamber (outlet


side).
2. Unbolt and remove inlet cone (inlet side).
3. Loosen set screws at the wheel hub and remove
wheel (inlet side).
4. Unbolt both sets of bearings from support bars
(outlet side).
5. Remove shaft/bearing assembly (outlet side).
6. Replace bearings on drive shaft.

If the bearings cannot be removed from the shaft due


to corrosion or damage, the bearing plates can be
removed from the inner chamber. The shaft/bearing/
bearing plates can be removed as a complete
assembly from the fan inlet.

Housing
Inlet
Cone

Wheel

Shaft/Bearing
Assembly

Cover
Plate

1. Unbolt and remove inlet cone (inlet side).


2. Loosen set screws at the wheel hub and remove
wheel (inlet side).
3. Remove bolts from drive bearing plate (outlet side).
4. Remove bolts from wheel bearing plate (inlet side).
5. Pull shaft/bearing/bearing plate assembly out of
the fan housing (inlet side).
6. Replace bearings on shaft/bearing/bearing plate
assembly.

Inlet
Cone

Shaft/Bearing/
Bearing Plate Assembly
Wheel

Housing

Models TCF and Model QEI/QEID Centrifugal

Troubleshooting
Problem

Cause

Corrective Action

Wheel Rubbing Inlet

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars
on shaft.

V-Belt Drive

Tighten sheaves on motor/fan shaft. Adjust belt tension. Align sheaves


properly (see page 6). Replace worn belts or sheaves.

Bearings

Replace defective bearing(s). Lubricate bearings. Tighten collars and


fasteners.

Wheel Unbalance

Clean all dirt off wheel. Check wheel balance, rebalance in-place if
necessary.

Fan

Check wheel for correct rotation. Increase fan speed.

Duct System

See pages 3 and 4.

Fan

Decrease fan speed.

Duct System

Resize ductwork. Access door, filters, grilles not installed.

Duct system has more or less


restriction than anticipated

Change obstructions in system. Use correction factor to adjust for


temperature/altitude. Resize ductwork. Clean filters/coils. Change fan
speed.

Fan

Check rotation of wheel.

Duct System

Resize ductwork. Check proper operation of face and bypass


dampers. Check filters and access doors.

Electrical Supply

Check fuses/circuit breakers. Check for switches turned off or


disconnected. Check for correct supply voltage.

Drive

Check for broken belts. Tighten loose pulleys.

Motor

Assure motor is correct horsepower and not tripping overload


protector.

Lubrication

Check for excessive or insufficient grease in the bearing.

Mechanical

Replace damaged bearing. Relieve excessive belt tension. Align


bearings. Check for bent shaft.

Belts

Adjust tightness of belts. Replacement belts should be a matched set.

System Unbalance

Check alignment of shaft, motor and pulleys. Adjustable pitch pulleys


with motors over 15 hp motors are especially prone to unbalance.
Check wheel balance, rebalance if necessary.

Excessive Noise

Volume Too Low

Volume Too High

Static Pressure Wrong

Excessive Power Consumption


High Horsepower

Fan Doesnt Operate

Bearings Overheated

Excessive Vibration

Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from
the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option
when returned to our factory, transportation prepaid. Motors are warranted by the motor manufacturer for a period of
one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the
nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.

Greenheck Catalogs Model TCF and Models QEI/QEID


provide additional information describing the equipment, fan
performance, available accessories, and specification data.

AMCA Publication 410-96, Safety Practices for Users and


Installers of Industrial and Commercial Fans, provides
additional safety information. This publication can be
obtained from AMCA International, Inc. at www.amca.org.

Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com

459968 TCF and QEI/QEID, Rev. 3, July 2008

Copyright 2008 Greenheck Fan Corporation

PN 473681
Vari-Green Motor
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble,
install, operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property damage!

Vari-Green Motor
The Vari-Green Motor is an electrically
commutated (EC) motor that uses 115V
single phase input power and internally
converts it to a DC power supply which
provides an 80% turndown capability
and increased energy savings.

General Safety Information


Only qualified personnel should install this fan. Personnel
should have a clear understanding of these instructions
and should be aware of general safety precautions.
Improper installation can result in electric shock, possible
injury due to coming in contact with moving parts, as well
as other potential hazards. Other considerations may
be required if high winds or seismic activity are present.
If more information is needed, contact a licensed
professional engineer before moving forward.

DANGER
Always disconnect, lock and tag power source before
installing or servicing. Failure to disconnect power
source can result in fire, shock or serious injury.

CAUTION
When servicing the fan, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.

CAUTION
Precaution should be taken in explosive
atmospheres.

1. Follow all local electrical and safety codes, as well as


the National Electrical Code (NEC) and the National
Fire Protection Agency (NFPA), where applicable.
Follow the Canadian Electric Code (CEC) in Canada.
2. The rotation of the wheel is critical. It must be
free to rotate without striking or rubbing any
stationary objects.
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than max cataloged fan
RPM. Adjustments to fan speed significantly effects
motor load. If the fan RPM is changed, the motor
current should be checked to make sure it is not
exceeding the motor nameplate amps.
5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with
the equipment.
7. Never open access doors to a duct while the fan
is running.

Vari-Green Motor

Installation
1. Install motor in accordance with local codes. Verify
fasteners holding motor to fan are properly secured
and wheel is properly secured on motor shaft.

3. Energize motor and check for proper rotation.


Rotation should be CCW when viewing the
shaft end.

2. Wire motor based on mode of operation.


(See attached wiring diagrams.)

4. Adjust motor speed to verify the proper motor


speed controller functionality.

Operation
The Vari-Green motor offers 3 different control options.
Follow the correct wiring diagram based on the control
option desired.

Motor mounted potentiometer


A dial is mounted on the case of the motor
to adjust the speed. Use a screwdriver to
turn the potentiometer to adjust the speed
of the motor.

NOTES
2 VDC IS 15% AND 10 VDC IS 100%
OF NAMEPLATE RPM.
0-1.9 VDC IS OFF.

0-10VDC Control Signal


This option is selected when the user wants to remotely
control the speed of the motor. A third-party controller
is installed by others that will give the motor a 0-10VDC
signal along with a 24VAC source to power the controls
in the motor. The VA requirement for the 24VAC source
is 0.70. The motor will operate within the 2-10VDC
range, while 0-1.9VDC the motor will be off.
2

Vari-Green Motor

Vari-Green Remote Mounted


Speed Control
Installation Overview:
In addition to supplying the fan with power, a
3-wire control cable will need to be run from the fan
motor compartment to the location of the remote
speed controller.
The speed controller will mount to a standard
single-gang 2x4 junction box. If other mounting
methods are required, consult the factory.
The maximum distance from the fan to the
speed controller is 100 feet. If a greater distance is
required, signal loss may occur and cause the fan to
operate erratically.
Note: There is a small switch on the rear of the speed
controller (Circled on back view). This adjusts the
output range of the speed controller.

The two settings are: 0-10V and 2-10V. The fan will
operate on either one of these settings.

The Vari-Green motor operates on a 2-10V active


signal. This means that from 0-1.9V, the motor is
off. If you require the speed controller to turn the
motor off, select the 0-10V setting.

> Note that even though the motor may not be


operating, high voltage power will still be present
at the motor. Make sure to disconnect power to
the fan before servicing.

Wiring
Verify that any power connected to the fan is
disconnected before making the control connections.
When the remote speed control option is ordered,
a 4x4 junction box containing a transformer will be
included in the motor compartment of the fan (on the
housing of an inline fan).
This wiring diagram is located on the junction box
cover for convenience.
Using 3-wire control cable, make the following
connections:
Transformer Box

Speed Controller

Yellow

Blue

Red

Vari-Green Motor

Remote Mounted
Speed Controlled Motor
Troubleshooting
If the motor RPM does not vary in accordance with
the dial input, perform a voltage check to ensure the
motor is receiving the correct control input.
At the speed controller:
Terminals

Desired Voltage

1-2

24VAC Nominal

1-3

0-10VDC
(varies with dial position)

If these voltage checks are as desired, verify all of the


connections inside the fan and make certain that they
are secure.
If the motor still does not operate as desired, please
consult the factory.

Maintenance
The Vari-Green motor utilizes brushless technology
with sealed bearings so no maintenance is required
other than keeping any accumulated debris from
collecting on the motor.

Features
Soft Start
All motors are a soft start motor. They will reliably
start at any speed setting.
Overload Protection
If the motor ever becomes overloaded, it will slow
itself down to the point where it is no longer being
overloaded. This means that the motor will never
burn itself out due to running into the service
factor as is a concern with many AC motors.
Locked Rotor Protection
If the motor ever sees a locked rotor condition, the
motor will automatically shut itself down. It will then
try to restart itself up to 3 times. If after the 3rd time
it still will not rotate, the motor will not attempt to
restart until after power is cycled.
Thermal Protection
The motor has a one-shot fuse thermal protector.
This is meant to protect the motor from a severe
temperature rise. With the motor softwares ability
to limit the motor if overloaded, the fuse is used as
a last resort to prevent a fire.

Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of
one year from the purchase date. Any units or parts which prove defective during the warranty period will
be replaced at our option when returned to our factory, transportation prepaid. Motors are warranted by the
motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during
this period, they should be returned to the nearest authorized motor service station. Greenheck will not be
responsible for any removal or installation costs.
As a result of our commitment to continuous improvement, Greenheck reserves the right to change
specifications without notice.
Greenheck Catalog provides additional information describing
the equipment, fan performance, available accessories, and
specification data.

AMCA Publication 410-96, Safety Practices for Users and


Installers of Industrial and Commercial Fans, provides additional
safety information. This publication can be obtained from AMCA
International, Inc. at: www.amca.org.

Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com
4

PN Vari-Green Motor, Rev. 1, May 2010

Copyright 2010 Greenheck Fan Corp

TAB 6

Part #463384

VCD Models
Vertical and Horizontal Mount

Installation, Operation, and Maintenance Instructions


This manual is the property of the owner, and is required for future maintenance. Please leave it with the
owner when the job is complete.

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Receiving and Handling

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Upon receiving dampers, check for both obvious


and hidden damage. If damage is found, record all
15
"4/1 5 on the bill of lading and
"8/file
necessary information
a claim with the final carrier. Check to be sure that
all parts of the shipment, including accessories, are
accounted for.

Safety WARNING:

Improper installation, adjustment, alteration,


service or maintenance can cause property
"8/1 5 Read the installation,
damage, injury or death.
operating, and maintenance instructions
thoroughly before installing or servicing this
equipment.

Dampers must be kept dry and clean. Indoor


storage and protection from dirt, dust and the
weather is highly recommended. Do not store at
temperatures in excess of 100F(37C).

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Due to continuing research, Greenheck reserves the right to change specifications without notice.

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Pre-Installation Guidelines
The basic intent of a proper installation is to secure the volume control damper into the opening in such a manner as to
prevent distortion and disruption of damper operation. The following items will aid in completing the damper installation in a
timely and effective manner.
1) Check the schedules for proper damper locations within the building. Visually inspect
the damper for damage.
2) Lift or handle damper using sleeve or frame. Do not lift damper using blades, linkage,
actuators, or jackshafting. When handling multiple sections assemblies, use sufficient
support to evenly lift at each section mullion (see drawing). Do not drag, step on, apply
excessive bending, twisting, or racking.

Spreader Bar

Attachments

3) Do not install screws in damper frame that will interfere with unexposed blade linkage
and prevent damper blades from opening and/or closing.
4) Damper must be installed into duct or opening square and free of twist or other
misalignment. Damper must not be squeezed or stretched into duct or opening. Out of
square, racked, twisted or misaligned installations can cause excessive leakage and/or
torque requirements to exceed damper/actuator design.

Multi section dampers

5) Damper and actuator must be kept clean, dry and protected from dirt, dust and other foreign materials prior to and after
installation. Examples of such foreign materials include but are not limited to:
a)
b)
c)
d)
e)

Mortar dust
Drywall dust
Firesafing materials
Wall texture
Paint overspray

6) Damper should be sufficiently covered as to prevent overspray if wall texturing or spray painting will be performed
within 5 feet (1.50m) of the damper. Excessive dirt or foreign material deposits on damper can cause excessive leakage
and/or torque requirements to exceed damper/actuator design.
7) ACCESS: Suitable access (actuators maintenance, etc.) must be provided for damper inspection and servicing. Where it
is not possible to achieve sufficient size access, it will be necessary to install a removable section of duct.

Electrical Guidelines
Electrical and/or pneumatic connections to damper actuators should be made in accordance with wiring and piping
diagrams developed in compliance with applicable codes, ordinances and regulations.

safety CAUTION !
Verify power requirements before wiring
actuator. Greenheck is not responsible for
any damage to, or failure of the unit caused
by incorrect field wiring.

Installation -

safety DANGER !

Electrical input may be needed for


this equipment. This work should be
performed by a qualified electrician.

Failure to follow instructions will void all warranties

1. Installing Multiple Damper Section Assemblies


A damper assembly is not restricted to a maximum number of sections, but must not exceed the section sizes and
overall sizes shown below.
The damper sections must be attached together


Maximum Section Sizes
Max Overall Size

Damper
with #10 x 34in.(19mm) max. sheet metal screws,


for Single section
for Multi-Section
1/4 in. (6mm) diameter nuts and bolts, tack or spot

Model

Dampers
Dampers
welds, or 316 in. (4mm) diameter steel pop rivets.

VCD-15, VCD-18
48 in. x 60 in. (1219mm x 1524mm)
84 in. x 60 in
Attachments must be spaced a maximum of 6 in.

(2133mm x 1524mm)
(152mm) on centers and a maximum of 2 in. (50mm)

VCD-20, VCD-23
48 in. x 74 in. (1219mm x 1879mm)
Unlimited
from corners. Attachments must be made on front

VCD-33, VCD-34
60 in. x 74 in. (1524mm x 1879mm)
Unlimited
face and back face (air entering and air exiting side)
VCD-40, VCD-42,
60 in. x 74 in. (1524mm x 1879mm)
Unlimited
of damper sections.

VCD-43
Two section high dampers require reinforcement using a 14 gauge (2mm), 5 in. (127mm) wide mullion as shown in Figure 6,
or two individually sleeved units stacked vertically, shown in Figure 7. When using two individually sleeved units, the sleeve
acts as the mullion, therefore no mullion is required (Mullions are not provided by Greenheck).


Installation (continued)

Multiple section damper frames can be


spotwelded or tek screwed together
(see figure 8 & 9).

14 ga.,
5 in. wide
Support
Mullion

Fig. 6

Fig. 8

Fig. 7
Fig. 9
2. If more than two sections wide, unit ships as a multiple section assembly and a single section together. The single
section is joined to the side of the multiple section where the jackshaft extends past the frame 4 inches.
3. D
 uct opening or opening square should measure 1/4 inch (6mm) larger than damper dimension and should be straight
and level.
4. If no holes are present in frame, drill 1/4 inch (6mm) diameter holes at 6 inch (52mm) centers and fasten frames together
with 1/4 inch (6mm) #20 (.03mm) bolts and nuts.
5. U
 se shims between damper frame and duct opening or opening space to prevent distortion of frame by fasteners
holding it in place. Brace at every horizontal mullion and vertically brace at every 8 feet (2.4m) of damper width for
strength. Dampers in high velocity (2000 fpm [610m per second]) may require more bracing. Note: Greenheck dampers
are specifically designed and engineered for structural integrity based on model and conditions. Attachment, framing,
mating flanges, and anchoring of damper assemblies into openings, ductwork, or walls is the responsibility of the
installer. Design calculations for these retaining and supporting members should be determined by field
engineers for that particular installation.
6. If
 damper actuator is to be mounted out of the airstream, the extension pin should extend
approximately 6 inches (152mm) beyond the frame. On jackshafted units, the jackshaft should extend
through the jackshaft bearing assembly and approximately, 6 inches (152mm) beyond the frame.
7. Individual damper sections, as well as entire multiple section assemblies must be completely square and
free from racking, twisting, or bending. Measure diagonally from upper corners to opposite
lower corners of each section.
A

Do not twist
or bow. Mount
damper plumb
in the opening.
AF = BE
AB = CD

Installation (continued)
8. D
 amper blades, axles, and linkage must operate without binding. Before system operation, cycle dampers after
installation to assure proper operation. On multiple section assemblies, all sections should open and close
simultaneously.

Damper Maintenance
Greenheck's dampers are designed to be trouble free and hassle free under normal operation. Dampers are to be installed
square and straight so as to prevent binding during operation. The following annual damper maintenance suggestions will
help to insure proper damper operation and increase the life expectancy of the damper.

Foreign Matter

Over the course of time, dirt and grime may collect on damper surfaces. The damper
surfaces should be cleaned to prevent hindrance to airflow.

Moving Parts

Make sure that parts such as linkage, bearings, blades, etc. that are intended to move
freely, can do so. Lubricating these components can prevent possible rusting and
unnecessary friction increase. Use only a moli-spray oil or similar graphite based oil as
regular lubricating oil will attract dirt.

Bearings. Synthetic, oil impregnated, and ball bearings (without grease fittings) do not
require lubrication. Ball bearings with grease fittings require only minimal grease.

Closure

Remove foreign materials that may be interfering with blade closure or effective sealing
of the blades with each other or with the frame.

Operation

While operating the damper through its full cycle, check to see that the blades open and
close properly. If there is a problem, check for loose linkage, especially at the actuator.
Tighten the linkage where required.

Damper Trouble Shooting


The following is a cause and correction list for common concerns with the dampers.
Symptom

Damper does not fully open


and/or fully close

Actuator runs hot or makes a


humming noise

Possible Cause

Corrective Action

Frame is 'racked' causing blades to


bind on jamb seals

Adjust frame such that it is square and


plumb

Actuator linkage loose

Close damper, disconnect


power, adjust and tighten
linkage

Defective motor

Replace

Screws in damper linkage

Locate screws and remove

Actuator linkage hitting wall or floor

Damper installed too far into wall. Move out


to line
designated on damper label

Contaminants on damper

Clean with a non oil-based


solvent (see Damper
Maintenance)

Actuator type is MP-3754 or MP3756 (stall type actuator)

None required since this normal for stall


type actuators

Actuator prohibited from


reaching end of stroke

Disconnect linkage from


jackshaft, open damper, power actuator to
end of spring, tighten linkage. Verify amp
draw.

Warranty
Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the
purchase date. Any units or parts which prove to be defective during the warranty period will be repaired or replaced at
our option. Greenheck shall not be liable for damages resulting from misapplication or misuse of its products. Greenheck
will not be responsible for any installation or removal costs. Greenheck will not be responsible for any service work or
backcharges without prior written authorization.
Copyright 2006 Greenheck Fan Corporation
#463384 VCD IOM Rev. 5 July 2006


TAB 7


3900 Dr. Greaves Rd.

Kansas City, MO 64030

(816) 761-7476

FAX (816) 765-8955

OPERATION & MAINTENANCE INSTRUCTIONS


MODELS: All FSD and SD Dampers
Regular maintenance is essential to ensure that a building's smoke-control system will perform as intended under fire and smoke
conditions. Regular maintenance should include periodic testing of all equipment associated with the smoke-control system such
as initiating devices, fans, dampers, controls, etc. Ruskin recommends each fire/smoke damper be cycled and tested every 6
months and in accordance with NFPA92A recommendations and local codes.

MAINTENANCE
Check actuator and tighten linkage if necessary.
Clean damper blades and other working parts if necessary.
Lubricate linkage, bearings and other moveable parts with a silicone lubricant. Do not use petroleum-based products as
they could cause excessive dust collection.
Operate (open and close) the damper via the actuator (see note).
Check the blades to make sure they completely close and re-open.
Consult Ruskin if problems are encountered.

TESTING FIRE/SMOKE DAMPERS


Use a moderate heat source and heat the thermal disc found "in the air-stream" on the fire/smoke damper. Caution: too much
heat may damage the thermal disc.
The disc will dimple and cause the flow of electricity, to the actuator, to stop. The damper blades will close.
Allow the disc to cool. Press the reset button on the outside of the damper. Flow of electricity to the actuator will resume and
the damper blades will open.
Note: If possible, the damper should be operated under normal airflow conditions.

MODELS: All (D)IBD and FD TYPE FIRE DAMPERS


Regular maintenance is essential to ensure that a building's life-safety system will perform as intended under fire and smoke conditions. Regular maintenance should include periodic testing of all equipment associated with the life-safety system such as fire
dampers. The interval of testing and maintenance varies widely depending on the duration of system operation, condition of fresh
air, amount of dust in return air, and other factors. NFPA 90A recommends testing of all fire dampers every four years as a minimum.

MAINTENANCE
(refer to notes)
Check closure springs. If defective, repair or replace.
Operate the damper by removing the fusible link and allowing the blades to drop or close.
(Caution: keep fingers and hands out of the blade package travel path.)
Check the damper for rust and/or corrosion.
Clean damper blades and lubricate the working parts. Do not use petroleum-based products as they could cause excessive dust collection.
Re-open the damper (move the blade package back to the top of damper) and replace the fusible link.

TESTING DAMPERS
(refer to notes)
Use a heat source and melt the fuse link or remove the fuse link and let the blade package drop. (Caution: keep fingers and
hands out of the blade package travel path.)
Check the blades to make sure they completely close and lock (if a lock is used).
Notes:
1.Due to their construction (including size) and/or accessibility, dynamic curtain type fire dampers may be very difficult and in
some cases impossible to test (close and re-open). If the damper is determined to be impossible to test, Ruskin recommends a
thorough examination to insure nothing exists which would prohibit the damper from closing. A thorough examination should
include checking the damper for squareness and the blade channel for obstructions.
2.Fire dampers may be easier to reopen from a specific side. Consult Ruskin for assistance.
3.If possible, fire dampers should be tested under normal airflow conditions.
FSDOM-406/replaces FSDOM-803

Ruskin 2006


3900 Dr. Greaves Rd.

Kansas City, MO 64030

(816) 761-7476

FAX (816) 765-8955

TS150 FIRESTAT FOR REOPENABLE FIRE AND SMOKE DAMPERS


OPERATION INSTRUCTIONS SUPPLEMENT
APPLICATION
The TS150 is a UL Classified heat responsive device which is used
in conjunction with Ruskin fire/smoke dampers. The TS150 is an
optional device which can be ordered with electric actuators or
pneumatic actuators and EP (electro/pneumatic) switches. The
TS150 allows the dampers to be reopened after the initial closure
for dynamic smoke control. The TS150 must be installed at the
factory and cannot be added in the field. Replacement TS150s
may be field installed with the approval of the local authority.

SMOKE DETECTION/TEST/POWER
FAILURE OPERATION
If smoke is detected, or during testing, or if power failure occurs,
the damper will close and lock. When the smoke signal ceases (or
smoke detector resets) , the test is complete or power is restored
the SYSTEM will automatically REMOTE RESET the damper to
the open position. The damper automatically resets if nuisance
alarms occur and the SYSTEM is reset. The damper may be
closed at any time by placing the MCP1 (optional) or other control
switch (by others) in the CLOSED position.

FIRE OPERATION
When the switch of a control panel (MCP) is in the NORMAL position and temperatures in excess of 165F/74C (212F/100C
optional) are detected, the damper will close and lock and the
damper CLOSED indicator light on the control panel will light.
The damper remains closed until the override signal for smoke
management from a remote command station is present and the
duct temperature has not exceeded the high limit. The high limit
temperature sensor prevents the damper from reopening when
duct temperature is above the damper's UL555S degradation test
temperature of 250F/121C or 350F/177C. Upon cessation of
the fire condition, the damper can be reopened by pressing the
RESET button on the TS150 assembly. At no time will the damper
disengage from the actuator. The integral SP100 will positively
communicate to the fire commander via the control panel the position of the damper for smoke management purposes.
Refer to the appropriate damper installation instructions for details
on damper installation. All electrical wiring and connections to the
Fire-Stat must be in accordance with the standards of the authorities having jurisdiction.

SEE COMPLETE
MARKING
ON PRODUCT

ITEM
1. TS-150 Fire Stat
2. Adjustable Connecting
Rod
3. Flex Conduit
4. Damper Frame
5. Actuator or EP Switch

ITEM
6. Over-Center Lock
7. Damper Sleeve
8. FAST, PFMA or conventional mounting angles
9. Sleeve to Duct
Connection (by others)

S1 and S2 Switch AMP Ratings: 15 AMPS, @ 24, 125 or 250 VAC 1/2
AMP, @ 125 VDC, 1/4 AMP, @ 250 VDC
Blue

Yellow

Blue

Yellow

FS Primary
Heat Sensor
Manual
Reset

Brown

Orange
Brown

Black
HL High Limit
Temp. Sensor
Manual Reset

BY OTHERS

BLUE

II-TS150-1007/Replaces II-TS150-205

BLUE

Ruskin 2007

3900 Dr. Greaves Rd.


Kansas City, MO 64030
(816) 761-7476
FAX (816) 765-8955
www.ruskin.com

TAB 8

PARTS LIST CP207F-PL (CONTINUED)

SERIES 1510 PUMPS

11/2BB & 11/2BC


ITEM
NO.
DESCRIPTION
Parts Common To Both Size Pumps
8
Volute
Wear Ring
Volute Drain Plug (4)
3
Volute Capscrew (12)
11
Volute Gasket
15
Coupler
14
Coupler Key (Straight) Aug. 1989 (H98) & After
14
Coupler Key (Woodruff) July 1989 (G98) & Before

BRONZE
FITTED
P41780

P39020
P03470
P48690
P49373
H32600

PUMP CONSTRUCTION
BRONZE FITTED
ALL
WITH WEAR RING
IRON
*P44136
P41780
P48660

P39020
P39030
P03470
P03470
P48690
P48690
See Coupler Selection Table, Page 48
P49373
P49373
H32600
H32600

ALL
BRONZE
P41800

P39470
S04180
P48690
P49373
H32600

For ANSI/OSHA Coupling Guard & Bracket Kit Selection, See Chart on Page 49

Parts for Pumps With 11/4" Shaft At Seal


5
Impeller (State Diameter) 91/2" Full Dia.
6
Impeller Washer
12
Volute Coverplate
12
Volute Coverplate - F Construction
4
Seal Kit
4
EPT Seal Kit
2
Bearing Frame Assembly Consisting of:
17
Bearing Frame
19 & 22
Shaft & Sleeve Kit
20
Bearing Cap
25
Ball Bearing - Pump End
26
Ball Bearing - Coupler End
22
Shaft Sleeve
7
Impeller Capscrew
9
Impeller Lockwasher
10
Impeller Key (Straight) Aug. 1989 (H98) & After
10
Impeller Key (Woodruff) July 1989 (G98) & Before
18
Spring Washer
21
Bearing Cap Capscrew (4)
13
Water Slinger
1
Support Foot - Motor Frames 143T-145T,182T-184T, 213T
Parts for Pumps With 15/8" Shaft At Seal
5
Impeller (State Diameter) 91/2" Full Dia.
6
Impeller Washer
12
Volute Coverplate
12
Volute Coverplate - F Construction
4
Seal Kit
4
EPT Seal Kit
2
Bearing Frame Assembly Consisting of:
17
Bearing Frame
19
Shaft
20
Bearing Cap
25
Ball Bearing - Pump End
26
Ball Bearing - Coupler End
22
Shaft Sleeve
7
Impeller Capscrew
9
Impeller Lockwasher
10
Impeller Key (Straight) Aug. 1989 (H98) & After
10
Impeller Key (Woodruff) July 1989 (G98) & Before
18
Spring Washer
21
Bearing Cap Capscrew (4)
13
Water Slinger
1
Support Foot - Motor Frames 213T-215T, 254T-256T
1
Support Foot - Motor Frames 284TS-286TS

P78523
P46380
186495
P61451
186862
186861
185011
P77103
185308
P75606
186002
186001
185140
P52350
J23874
P49369
H32500
J92558
J92291
P53550
186906

P78523
P46380
186495
P61451
186862
186861
185011
P77103
185308
P75606
186002
186001
185140
P52350
J23874
P49369
H32500
J92558
J92291
P53550
186906

P78253
P78523
P46381
P46390
186495
P56799
NONE
NONE
186860
186862
NONE
186861
185012
185013
P77103
P77103
+P78927 +P79018
P75606
P75606
186002
186002
186001
186001
185141
NONE
P52350
P52350
J23874
J23874
P49369
P49369
H32500 H32500
J92558
J92558
J92291
J92291
P53550
P53550
186906
186906

P78251
P51230
P51540
P51541
186543
185225
185014
P77161
P79027
P75612
186571
186572
185142
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906

P78251
P51230
P51540
P51541
186543
185225
185014
P77161
P79027
P75612
186571
186572
185142
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906

P78522
P46382
P51540
NONE
186544
NONE
185015
P77161
P79027
P75612
186571
186572
185143
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906

P78251
P51250
P51560
NONE
186543
185225
185016
P77161
P79028
P75612
186571
186572
NONE
P13800
J23875
P49372
H32700
J92560
DJ0066
P53720
186905
186906

* Includes wear ring.


+ - Shaft only. Does not include sleeve or retaining compound.
Factory recommended spare parts.

19

BELL & GOSSETT

PARTS LIST

Replacement Parts for

Standard
Design Pumps

SERIES 1510

CP-207F-PL

PARTS LIST CP207F-PL (CONTINUED)

SERIES 1510 PUMPS

How to use this


PARTS LIST
The pump nameplate identifies the pump by discharge size, and the maximum
impeller diameter of the unit. The pump construction, flow, head, serial number and
manufacture date are also listed as identified in the example below.
Impeller
Diameter

Size

Construction

Series

Serial No.

Date Manufactured
(October, 1988)

Flow

Head

HP

RPM

The nameplate identifies the pump in the example as a Series 1510, size 5G in bronze
fitted (BF) construction. A 123/4" impeller is beeing provided to meet 990 GPM at 150 ft.
at 1750 RPM. The serial number specifically identifies the unit for future reference. DO
NOT REMOVE THE NAMEPLATE. It is important when ordering replacement parts to
furnish complete nameplate data.
The 1510 pump is furnished with both Standard Seal or Stuffing Box configuration. The Standard Seal pump has no seal designation after the Series number on
the nameplate. If the example pump was of Stuffing Box configuration, the nameplate would show it to be a 1510-S, 1510-PF or 1510-D pump. Parts for Stuffing
Box type pumps are covered under the CP-206D-PL parts list.
To insure the correct parts are selected, use the following procedure:
1. Determine from the nameplate the pump size, seal configuration, pump construction and impeller diameter.
2. Measure shaft sleeve diameter at the seal.
3. Refer to the index for the page number of the parts breakdown for the specific size
pump.
4. Find the proper column in the parts breakdown for the pump construction involved.
5. Select part numbers, using the numbered drawings on page 4 for identification.
Where shaft diameter affects parts selection, use the measurement secured in
Step 2.
6. Bearing frames vary with motor frame sizes. Use the motor frame number (found
on the motor nameplate) to select the proper bearing frame from the chart on
page 5.

4
17

BEARING FRAME

COUPLER

SPRING
WASHER
18

26

10

IMPELLER
KEY

22

IMPELLER
CAPSCREW

BALL BEARING FRAME ASSEMBLY


EXPLODED VIEW

20

BEARING
CAP

VOLUTE MOUNTING
CAPSCREW

P77375
P76922

BEARING LOCKWASHER
BEARING LOCKNUT

USED ON LARGE BEARING FRAMES ONLY


MANUF. BEFORE JAN. 1995 (A59)

VOLUTE

IMPELLER CAPSCREW

IMPELLER WASHER

IMPELLER

IMPELLER
LOCKWASHER

SLINGER

SHAFT
SLEEVE

IMPELLER LOCKWASHER
IMPELLER KEY

GREASE FITTING CAPSCREWS


WATER
PUMP END

13

SEAL KIT

BEARING CAP

21

VOLUTE GASKET

BALL BEARING
PUMP END

25

VOLUTE CAPSCREW

SHAFT
19

VOLUTE COVER PLATE


WATER SLINGER

BEARING FRAME ASSEMBLY

BALL BEARING
COUPLER END 14
COUPLER
KEY

SUPPORT FOOT

COUPLER KEY

BEARING CAP COUPLER END (NOT SHOWN) IS ONLY


USED ON THE EXTRA LARGE BEARING FRAME

GREASE FITTING
COUPLER END

- Factory recommended
spare parts.

MOTOR

BEARING FRAME MOUNTING CAPSCREW

SERIES 1510
Standard Seal Design Pump
Exploded View

PARTS LIST CP207F-PL (CONTINUED)


SERIES 1510 PUMPS

1 /2"AC

2"AC

21/2"AB

3"AC
4"AC
5"A
11/4"BC
11/2"BC
2"BC
21/2"BB
3"BC
4"BC
5"BC
6"BC
2"E
3"E
4"E
5"E
6"E
2"G
3"G
4"GB
5"G
6"G

X
X

X
X
X

X
X

XX
X
X
XX
X

XX
XX
X
XX
X
X
X
X
X
X
X
X
X

XX

X
X

XX
X
X
X
X
X
X
X
X
X

XX

XX

XX

X
X

X
X
X
X
X
X

X
X

XX

XX

XX

XX

X
X
X

X
X
X
X
X

XX

XX

XX

XX

X
X
X

X
X
X

XX

XX

XX

254T

X
X
X

XX
XX

XX

213T

X
X
X
X
X
X

XX
XX
XX

XX
XX

254T

X
X
X
X
X
X
X
X
X

X
X

XX
XX
XX
XX
XX
XX
XX

256T

X
X
X
X
X
X
X
X

X
X

XX
XX
XX
XX
XX
XX
XX
XX
XX

X
X
X
X

X
X
X

X
XX

XX
XX
XX
XX
XX
XX
XX
XX
XX

X
X
X
X

X
X

XX

XX

XX
XX
XX
XX

XX
XX

X
X

X
XX
XX
XX

XX
XX
XX
XX

XX
XX

X
X

XX
XX
XX

XX

XX

XX

XX
XX
XX

XX

XX
XX

XX

15/8" Diameter Shaft at Seal


23/8" Diameter Shaft at Seal
PART NO.
PART NO.
LARGE
EXTRA LARGE 185320
185014 (Bronze Fitted)
BEARING
BEARING (Bronze Fitted)
185015 (All Iron)
FRAME
FRAME*
185016 (All Bronze)
284T 284TS 286T 286TS 324T 324TS 326T 326TS 364T 364TS 365T 365TS 404TS 326T 364TS 365TS 404TS 405TS

Above chart refers to current production pumps only

X
X
X

XX
XX
XX

XX
XX

215T

X FOR 1150 RPM OR 1750 RPM APPLICATIONS


XX FOR 3450 RPM APPLICATIONS
* USED ON 5G & 6G PUMPS WITH IMPELLER DIAMETER LARGER THAN 121/2"

11/4"AC

56

Frame #
SIZE

11/4" Diameter Shaft at Seal


PART NO.
SMALL
185011 (Bronze Fitted)
BEARING
185012 (All Iron)
FRAME
185013 (All Bronze)
143T 145T 182T 184T 213T 215T

Series 1510 Pump Bearing Frame


Selection Chart Standard Seal T Frame Motors

PARTS LIST CP207F-PL (CONTINUED)


SERIES 1510 PUMPS

PARTS LIST CP207F-PL (CONTINUED)

SERIES 1510 PUMPS

Sleeve Bearing Frame Assembly


for Pumps with 11/4 Shaft at Seal
32

OIL WELL COVER ASSEMBLY

OIL WICKING SPRING

31

OIL WICK
34

30

SLEEVE BEARING
REAR

14

SHAFT & SLEEVE ASSEMBLY

COUPLER KEY

9
10

13

IMPELLER KEY

WATER
SLINGER

IMPELLER
LOCKWASHER
7

IMPELLER
CAPSCREW

SLEEVE BEARING GASKET


28
27

BEARING
FRAME

ITEM
NO.
2
27
30
29
34
28
7
9
10
14
33
32
31
13

33

OIL CUP

DESCRIPTION
Bearing Frame Assembly
Consisting of:
Bearing Frame
Shaft & Sleeve
Sleeve Bearing (Front)
Sleeve Bearing (Rear)
Sleeve Bearing Gasket (Included with Bearings)
Impeller Capscrew
Impeller Lockwasher
Impeller Key (Straight) Aug. 1989 (H98) & After
Impeller Key (Woodruff) July 1989 (G98) & Before
Coupler Key (Straight) Aug. 1989 (G98) & After
Coupler Key (Woodruff) July 1989 (G98) & Before
Oil Cup
Oil Well Cover Before June 1965 (EE)
Oil Well Cover After June 1965 (FE)
Oil Wick Set (2 Sets Required)
Water Slinger

SLEEVE BEARING FRONT


29

SLEEVE BEARING CAPSCREW

PART
NO.
186660
P11450
186628
186659
186658
P11390
P52350
J23874
P49369
H32500
P49373
H32600
P14010
N/A
P14051
118395
P53550

Factory recommended spare parts.

47

PARTS LIST CP207F-PL (CONTINUED)

SERIES 1510 PUMPS

Coupler Selection Table


PUMP SIZE
FOR PUMPS
WITH SMALL
BEARING FRAME
1" SHAFT
AT COUPLER

FOR PUMPS
WITH LARGE
BEARING FRAME
11/4" SHAFT
AT COUPLER

FOR
5G
AND
6G PUMPS
WITH EXTRA LARGE
BEARING FRAME
17/8 SHAFT
AT COUPLER**

FRAME SIZE
56
143T-145T
182T-184T
213T
215T
254T
256T
213T
215T
254T
256T
284T
284T
286T
286T
284TS
286TS
324T
326T
324TS
326TS

SHAFT
SPACE
11/4"
13/4"
13/4"
21/2"
21/2"
21/2"
21/2"
33/4"
33/4"
33/4"
33/4"
33/4"
4"*
33/4"
4"*
33/4"
33/4"
4"
4"
33/4"
33/4"

H.P.
/2-3/4
1
1 1 /2 2 3
2 3 5 71/2
5 71/2 10
71/2 10 15
15 20
20 25
71/2
10
15
20
25
25
30
30
30
40
40
50
50
60

MOTOR
SHAFT
SIZE
5
/8"
7
/8"
11/8"
13/8"
13/8"
15/8"
15/8"
13/8"
13/8"
15/8"
15/8"
17/8"
17/8"
17/8"
17/8"
15/8"
15/8"
21/8"
21/8"
17/8"
17/8"

364T
365T
404TS
326T

4"*
4"*
4"*
53/8"

60
75
100
50

23/8"
23/8"
21/8"
21/8"

364TS

53/8"

60

17/8"

365TS

53/8"

75

17/8"

404TS

53/8"

100

21/8"

405TS

53/8"

125

21/8"

*6C and 8C, 5CB and 6CB, 5G and 6G


**SPACER TYPE COUPLER USED ON THESE PUMPS
TO OBTAIN COMPLETE COUPLER, SPECIFY BOTH HALVES AND SLEEVE.
Factory recommended spare parts.

48

COUPLER
186868
186869
186870
186871
186871
186873
P63240
186872
186872
P63239
186874
P63242
P63243
P63244
P63244
P63239
186874
P63245
P63247
P63242
P63244
P63248
P63250
P63253
P82096
P82097
P82096
2 REQD
P82158
2 REQD
P82158
P82141
P82161
P82162

SLEEVE FOR
WOODS
COUPLER
P78804(4J)
P78804(4J)
P78729(5J)
P78791(6J)
P78791(6J)
P78792(7S)
P78794(8S)
P78791(6J)
P78791(6J)
P78792(7S)
P78794(8S)
P78794(8S)
P78794(8S)
P78796(9S)
P78796(9S)
P78792(7S)
P78794(8S)
P78796(9S)
P78798(10S)
P78794(8S)
P78796(9S)

SPIDER FOR
LOVEJOY
COUPLER
P45540
P45540
P45540
P45532
P45532
P45532
P45532
P45532
P45532
P45532

P45532
P45532

P78798(10S)
P78802(11S)
P78802(11S)
P82098

P82098

P82142

P82142

P82144

Bell & Gossett

INSTRUCTION MANUAL
P81673

REVISION F

Series 1510 and 1510/Universal


Centrifugal Pumps
Installation, Operation and Service Instructions
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNERS USE.

Bell & Gossett

DESCRIPTION

PUMP APPLICATION

The Series 1510 centrifugal pump is a frame mounted pump


which features high efficiency, rugged construction, foot
mounted volute with back pullout bearing frame, center drop
out coupler and regreasable bearings. These features make
installation, operation and service easy to perform.

The standard Series 1510 centrifugal pump's bronze fitted


construction make it ideal for service with following liquids:
unheated domestic and fresh water, boiler feed water, condensate, hydronic cooling or heating, pressure boosting, general
pumping and benign liquids.
For other applications contact your local B&G Representative.

OPERATION LIMITS
Unless special provisions have been made for your pump by
Bell & Gossett, the operational limits for Series 1510 Pumps
are as follows:
Maximum Working Pressure
Listed on pump nameplate.
SEAL OPERATING LIMITS
Standard Seals
BUNA-PH Limitations 7-9; Temperature Range -40 to +225F
EPTH-PH Limitations 7-11; Temperature Range -40 to + 250F
For use on closed or open systems which are relatively free of
dirt and/or other abrasive particles.
Flushed Single Seals
PH Limitations 7-9; Temperature Range 0 to +250F
NOTE: On closed or open low pressure systems that contain
a high concentration of abrasives an external flush is required.

Flushed Double Seals


PH Limitations 7-9; Temperature Range 0 to +250F
NOTE: On closed or open low pressure systems that contain a
high concentration of abrasives an external flush is required.
Packing
PH Limitations 7-9; Temperature Range 0 to +200F
For use on open or closed systems which require a large
amount of makeup water, as well as systems which are subjected to widely varying chemical conditions and solids
buildup.
For operating temperatures above 250F a cooled flush is required
and is recommended for temperatures above 225F for optimum
seal life. On closed systems cooling is accomplished by inserting a
small heat exchanger in the flush line to cool the seal flushing fluid.
Flush-line Filters and Sediment Separators are available on special
request.

SAFETY
INSTRUCTIONS

WARNING

This safety alert symbol will be used in this manual and on the
pump Safety Instruction decal to draw attention to safety related
instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN
A SAFETY HAZARD.

ROTATING COMPONENTS

DISCONNECT AND LOCK OUT


POWER BEFORE SERVICING.
DO NOT OPERATE WITHOUT
ALL GUARDS IN PLACE.
CONSULT INSTALLATION
AND SERVICE INSTRUCTION
SHEET BEFORE OPERATING
OR SERVICING.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY
OR DEATH.
P70642

FIGURE 3

Your Series 1510 Pump should have the following safety


instruction decals located approximately as shown. If the
decals are missing or illegible contact your local B&G Representative for a replacement.

(2) Required
(1 each side)

Additional Safety Requirements:


1. Electrical connections to be made by qualified Electrician in
accordance with all National, State and Local codes.
2. Motor must have properly sized starter with properly sized
heaters to provide overload and undervoltage protection.
3. If pump, motor or piping are operating at extremely high or
low temperatures, guarding or insulation is required.
4. The maximum working pressure of the pump is listed on
the pump nameplate, do not exceed this pressure.

CAUTION
DO NOT RUN PUMP DRY,
SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL
REGULARLY FOR LEAKS,
REPLACE AS REQUIRED.
FOR LUBRICATION
REQUIREMENTS, CONSULT
SERVICE INSTRUCTIONS.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70644

Alternate
location

CAUTION
COUPLER ALIGNMENT IS
REQUIRED! LEVEL AND GROUT
PUMP BEFORE USE!
CHECK ALIGNMENT BEFORE
GROUTING, AFTER SYSTEM IS
FILLED, AFTER SERVICING
PUMP, AND AS REQUIRED.
CONSULT THE SERVICE
INSTRUCTIONS FOR DETAILS.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70820

WARNING
EYEBOLTS OR LIFTING
LUGS IF PROVIDED ARE
FOR LIFTING ONLY THE
COMPONENTS TO WHICH
THEY ARE ATTACHED.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY
OR DEATH.

P70643

ADDITIONAL SAFETY REQUIREMENTS:


ELECTRICAL SAFETY:
WARNING: Electrical Shock Hazard
Electrical connections to be made by a qualified
electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these
instructions could result in serious personal injury or death,
or property damage.
WARNING: Electrical Overload Hazard
Three phase motors must have properly sized
heaters to provide overload and undervoltage protection.
Single phase motors have built-in overload protectors.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
THERMAL SAFETY:
WARNING: Extreme Temperature Hazard
If pump, motor, or piping are operating at extremely
high or low temperatures, guarding or insulation is
required. Failure to follow these instructions could result in
serious personal injury or death, or property damage.

MECHANICAL SAFETY:
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
WARNING: Excessive System Pressure Hazard
The maximum working pressure of the pump is listed
on the nameplate, do not exceed this pressure. Failure to
follow these instructions could result in serious personal
injury or death, or property damage.
WARNING: Excessive Pressure Hazard
Volumetric Expansion
The heating of water and other fluids causes volumetric
expansion. The associated forces may cause failure of system components and release of high temperature fluids.
This will be prevented by installing properly sized and
located compression tanks and pressure relief valves.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.

PUMP LOCATION
Locate the pump so there is sufficient room for inspection,
maintenance and service. If the use of a hoist or tackle is
needed, allow ample head room.

FIGURE 4

WARNING: FALLING OBJECT HAZARD


Eyebolts or lifting lugs if provided are for lifting only
the components to which they are attached. Failure to follow these instructions could result in serious personal injury
or death, or property damage.
If lifting of the entire pump is required, do so with slings placed
under the base rails as shown.
The best pump location for sound and vibration absorption
is on a concrete floor with subsoil underneath. If the pump
location is overhead, special precautions should be undertaken to reduce possible sound transmission, consult a sound
specialist.
If the pump is not on a closed system, it should be placed as
near as possible to the source of the liquid supply, and located
to permit installation with the fewest number of bends or
elbows in the suction pipe.
The installation must be evaluated to determine that the Net
Positive Suction Head Available (NPSHA) meets or exceeds
the Net Positive Suction Head Required (NPSHR), as stated by
the pump performance curve.

IMPORTANT
Do not install and operate Bell & Gossett Pumps, 3D Valves,
Suction Diffusers, etc., in closed systems unless the system is
constructed with properly sized safety devices and control
devices. Such devices include the use of properly sized and
located pressure relief valves, compression tanks, pressure
controls, temperature controls, and flow controls as appropriate. If the system does not include these devices, consult
the responsible engineer or architect before making pumps
operational.

FIGURE 5

COMPRESSION TANK SHOULD


BE LOCATED ON THE
SUCTION SIDE OF THE PUMP
B&G REDUCING
VALVE

COLD WATER
SUPPLY

B&G ROLAIRTROL
AIR SEPARATOR

SUPPLY TO
SYSTEM

FROM BOILER
CHILLER OR CONVERTER

TYPICAL
PUMP
INSTALLATION

ISOLATION
VALVE

B&G

B&G
TRIP

LE

CIR

CU

DU

TY

IT S

ETT

ER

VAL
V

B&G SERIES
1510 PUMP
B&G SUCTION DIFFUSER

INSTALLATION

FOUNDATION BOLT

PIPE SLEEVE

This pump is built to provide years of service if installed properly and attached to a suitable foundation. A base of concrete
weighing 21/2 times the weight of the pump is recommended.
(Check the shipping ticket for pump weight.)
If possible, tie the concrete pad in with the finished floor. Use
foundation bolts and larger pipe-sleeves to give room for final
bolt location. (See Figure 6A.)

WASHER

FIGURE 6A

INSTALLATION OF
FOUNDATION BOLTS
BUILT-UP
CONCRETE FOUNDATION

FIGURE 6B

LEVELING OF PUMP BASE


ON CONCRETE FOUNDATION
NOTE:
TO KEEP SHIMS IN PLACE
ALLOW NON-SHRINKING
GROUT TO FLOW AROUND
HOLD DOWN LUGS
GROUT ONLY TO
TOP OF BASE RAIL

ALLOW 1" FOR SHIMS.


PLACE ON BOTH SIDES
OF ANCHOR BOLTS

PUMP BASE RAIL


PUMP BASE

GROUT
.
APPROX
1" GAP

LEVELING
Place the pump on its concrete foundation supporting it with
steel wedges or shims totaling 1" in thickness. These wedges
or shims should be put on both sides of each anchor-bolt to
provide a means of leveling the base. (See Figure 6B.)

CONCRETE FOUNDATION

IT IS VERY IMPORTANT THAT THE PUMP-BASE BE SET


LEVEL TO AVOID ANY MECHANICAL DIFFICULTIES WITH
THE MOTOR OR PUMP. THIS PUMP WAS PROPERLY
ALIGNED (IF FURNISHED WITH A MOTOR) AT THE FACTORY.
HOWEVER, SINCE ALL PUMP BASES ARE FLEXIBLE THEY
MAY SPRING AND TWIST DURING SHIPMENT. DON'T PIPE
THE PUMP UNTIL IT IS REALIGNED. AFTER PIPING IS
COMPLETED AND AFTER THE PUMP IS GROUTED-IN AND
BOLTED-DOWN, ALIGN IT AGAIN. IT MAY BE NECESSARY
TO RE-ADJUST THE ALIGNMENT FROM TIME TO TIME
WHILE THE UNIT AND FOUNDATION ARE NEW.

GROUTING
After the pump has been leveled, securely bolted to the floor,
and properly aligned, a good grade of non-shrinking grout
should be poured inside the pump base. To hold wedges or
shims in place, allow the grout to flow around them. (See
Figure 6B).

ROTATION
Pump rotation is clockwise when viewed from back of the
motor. An arrow is also located on the pump to show the
direction of rotation.

COUPLER ALIGNMENT
All alignment should be done by moving or shimming the
motor only. Adjustments in one direction may alter alignment
in another. Therefore, check alignment in all directions after a
correction is made. Black rubber sleeves have different
horsepower load ratings then orange Hytrel sleeves, they
should not be interchanged.

1. To check angular misalignment, mount the dial indicator


base to one coupler half, or shaft, and position the dial indicator button on the front or rear face of the opposite coupler half. Set the dial to zero. Rotate both coupler halves
together, making sure the indicator button always indicates off the same spot. Misalignment values within 0.004"
TIR per inch of coupler radius are permissible.
2. To check parallel misalignment, mount the dial indicator
base to one coupler half, or shaft, and position the dial indicator button on the outside diameter of the opposite coupler half. Set the dial to zero. Rotate both coupler halves
together, making sure the indicator button always indicates off the same spot. Misalignment within 0.004" TIR is
permissible.
AMOUNT OF
PARALLEL
MISALIGNMENT

STRAIGHT EDGE

WARNING: UNEXPECTED STARTUP HAZARD


Disconnect and lockout power before servicing.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
Standard Sleeve Type Coupler with Black Rubber Sleeve

PARALLEL ALIGNMENT CHECK

FIGURE 7A

Before aligning the coupler, make sure there is at least 1/8" end
clearance between the sleeve and the two coupler halves.
1. Check angular misalignment using a micrometer or caliper.
Measure from the outside face of one flange to the outside
face of the opposite flange at four points 90 apart. Refer to
figure 7B. DO NOT ROTATE COUPLER. Misalignment up to
1
/64" per inch of coupler radius is permissible.
2. At four points 90 apart (DO NOT ROTATE COUPLER),
measure the parallel coupler misalignment by laying a
straight edge across one coupler half and measuring the
gap between the straight edge and opposite coupler half.
Up to a 1/64" gap is permissible. Refer to figure 7A.

DISTANCES ACROSS
COUPLER FLANGES
SHOULD BE EQUAL
(CHECK 4 PLACES)
ANGULAR ALIGNMENT CHECK

For Fine Alignment, Orange Hytrel Sleeves,


3500 RPM Operation, or All Other Coupler Types
Use a dial indicator when greater alignment accuracy is
required. Use the following alignment tolerances unless specified otherwise by the coupler manufacturer. On sleeve type
couplers make sure there is at least 1 / 8 " end clearance
between the sleeve and the two coupler halves.

FIGURE 7B

WARNING: ROTATING COMPONENT HAZARD


Do not operate pump without all guards in place.
Failure to follow these instructions could result in serious personal injury or death, or property damage.

PIPING

PIPING

Always install a section of straight pipe between the suction


side of the pump and first elbow or install a B&G Suction
Diffuser. This reduces turbulence of the suction by straightening out the flow of liquid before it enters the pump. The length
should be equal to five times the diameter of the pipe.

As a rule, ordinary wire or band hangers are not adequate to


maintain alignment. It is very important to provide a strong,
rigid support for the suction and discharge lines.

Be sure to eliminate any pipe-strain on the pump. Support the


suction and discharge pipes independently by use of pipe
hangers near the pump. Line up the piping so that the boltholes in the pump flanges match the bolt-holes in the pipe
flanges. DO NOT ATTEMPT TO SPRING THE SUCTION OR
DISCHARGE LINES INTO POSITION. Coupling and bearing
wear will result if suction or discharge lines are forced into
position. The code for Pressure Piping (A.S.A.B. 31.1) lists
many types of supports available for various applications.

Where considerable temperature changes are anticipated,


fittings for absorbing expansion should be installed in the
system in such a way as to avoid strain on the pump.
On an open-system with a suction-lift, use a foot-valve of
equal or greater area than the pump suction piping. Prevent
clogging by using a strainer at the suction inlet next to the
foot-valve. The strainer should have an area three times that of
the suction pipe with a mesh hole diameter of no less than 1/4".
When using an isolation base, flexible piping should be used
on both the suction and discharge sides of the pump.
5

A Triple Duty Valve, such as the one manufactured by Bell &


Gossett, installed in the discharge line will serve as a check
valve to protect the pump from water hammer, as an isolation
valve for servicing and for throttling.

NOTES:
1. The pipeline should have isolation valves around the pump
and have a drain valve in the suction pipe.
2. When installing the suction and discharge connections to a
threaded pump housing the use of teflon tape sealer or a
high quality thread sealant is recommended.

PUMP INSULATION
When insulating a Series 1510 pump, ensure that the bearing
assembly grease fittings remain accessible and visible. The
vent slots on the sides and bottom of the bearing assembly
should remain uncovered and completely open.

LUBRICATION

GENERAL INSTRUCTIONS

While pump is running regrease pump bearing with NLGI


Grade #2 lithium base petroleum grease after every 2500
hours of operation or every 6 months whichever occurs first.

1. Keep this pump and motor properly lubricated.

Lubricate motor per motor manufacturers instructions.

2. When there is a danger of freezing, drain the pump.


3. Inspect pump regularly for leaky seals or gaskets and loose
or damaged components. Replace or repair as required.

HEX GUARD EXPLODED VIEW FOR TYPICAL INSTALLATION


FIGURE 8

INNER GUARD

OUTER GUARD

LOCATE SUPPORT ARM


BETWEEN OUTER GUARD ENDS.
ALIGN THE ARM WITH HOLES IN
THE OUTER GUARD AND HOLES IN
THE SADDLE BRACKET.

ATTACH SUPPORT BRACKET


TO PUMP SIDE OF SUPPORT
THE SUPPORT BRACKET
ATTACHES INSIDE HERE
INLINE WITH BOLT

NUT
LOCKWASHER

CAPSCREW
FLAT WASHER

SUPPORT BRACKET

SPACER WASHER
MOTOR SADDLE BRACKET
ATTACH TO MOTOR SADDLE

THIS OPTION USED IN PLACE OF SPACER WHERE


OVERALL LENGTH OF GUARD EXCEEDS 12 INCHES
OR GUARD WIDTH IS OVER 10 INCHES ACROSS
THE FLATS.

STANDARD MECHANICAL SEAL CONSTRUCTION


VENT PLUG

FIGURE 9

VOLUTE

IMPELLER

VOLUTE GASKET

COVERPLATE

BEARING FRAME

SEAL ASSEMBLY
SHAFT

SLINGER
BEARING FRAME
CAPSCREWS
SHAFT SLEEVE

SUPPORT FOOT

IMPELLER KEY
SUPPORT FOOT CAPSCREWS

IMPELLER
WASHER

IMPELLER CAPSCREW

IMPELLER LOCK WASHER

DRAIN PLUG

STUFFING BOX CONSTRUCTION


COVERPLATE
CAPSCREWS

FIGURE 10

BEARING
FRAME

COVERPLATE

VOLUTE
GASKET

VOLUTE

IMPELLER

FLUSHING
TUBE
LANTERN
RING
PACKING
PACKING
GLAND

SHAFT

SLINGER
SHAFT
SLEEVE
BRACKET

IMPELLER
KEY
IMPELLER
W

ASHER
VOLUTE
CAPSCREWS

IMPELLER
CAPSCREW
DRAIN PLUG

IMPELLER
LOCK
WASHER

FIGURE 12
1510-D

FIGURE 11
1510-S
MOTOR END

MOTOR END
O-RING

COVERPLATE
FOR 11/4" SEAL
113/32"

FOR 15/8" AND


23/8" SEAL 11/4"
SEAL LOCKING COLLAR
O-RING
SEAL CAP BOLTS

O-RING
SEAL CAP

O-RING

SERVICE INSTRUCTIONS
WARNING: UNEXPECTED STARTUP HAZARD
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious personal injury or death, or property damage.

3. Loosen set screws in both coupler halves and slide each


half back as far as possible on its shaft. Remove coupler
sleeve. Where a full diameter impeller is used, it may be
necessary to remove the pump side coupler half and to
slide the motor back on its base in order to gain sufficient
clearance to remove the pump assembly from the volute.

1. Close valves on suction and discharge sides of pump. (If


no valves have been installed, it will be necessary to drain
the system.)

4. Remove support foot capscrews. Loosen volute capscrews, do not remove them. Use capscrews in the jack
screw holes (Not on 8G). Loosen the pump assembly from
the volute.

CAUTION: EXTREME TEMPERATURE HAZARD


Allow pump temperature to reach acceptable levels
before proceeding. Open drain valve, do not proceed until
liquid stops coming out of drain valve. If liquid does not
stop flowing from drain valve, isolation valves are not sealing and should be repaired before proceeding. After liquid
stops flowing from the drain valve, leave valve open and
continue. Remove the drain plug located on the bottom of
the pump housing. Do not reinstall plug or close drain valve
until re-assembly is completed. Failure to follow these
instructions could result in property damage and/or moderate personal injury.
2. Remove the Hex Coupler Guard as follows (see figure 8):
a. Remove the two cap screws that hold the outer (motor
side) coupler guard to the support bracket(s).
b. Spread the outer guard and pull it off the inner guard.
NOTE: Do not spread the inner and outer guards more
than necessary for guard removal. Over spreading the
guards may alter their fit and appearance.
c. Remove the cap screw that holds the inner guard to the
support bracket.
d. Spread the inner guard and pull it over the coupler.

WARNING: EXCESSIVE PRESSURE HAZARD


Make certain internal pressure of the pump is relieved
before continuing. Failure to follow these instructions could result in serious personal injury or death, or property damage.
Remove seal flushing tube, if used.
Remove the volute capscrews and remove the pump
assembly from the volute.
Continue to the section which pertains to your pump type.
1510 and 1510-F
With Standard Mechanical Seal Figure 9
5. Remove the impeller capscrew, lock washer and washer.
Remove the impeller.
6. Remove the rotating portion of the seal, use a screwdriver
to loosen the rubber ring.
7. Remove the seal insert along with the insert gasket and
retainer (if used).
8. Thoroughly clean the shaft sleeve and the coverplate seal
cavity. Inspect for surface damage like pitting, corrosion,
nicks or scratches. Replace if necessary.

9. Lubricate the shaft sleeve and coverplate seal cavity with


soapy water (do not use petroleum lubricant). Install a new
insert gasket and a new seal insert with indentation side
down into the cup.

9. Assemble coverplate to bracket, tighten capscrews per


torque chart (See Table 1). Assemble seal cap to coverplate, tighten hex nuts on seal cap bolts per torque chart
(See Table 1).

10. Slide a new rotating seal assembly onto the shaft sleeve.
With a screwdriver push on the top of the compression
ring until the seal is tight against the seal insert. Install seal
spring, with narrow end toward seal.

10. Go to Step 11 of 1510 Standard Mechanical Seal


Instructions.

11. Install impeller, impeller washer, lock washer and capscrew. Tighten capscrew per torque chart (See Table 1).
12. Install new volute gasket then install pump assembly into
volute. Tighten volute capscrews per torque chart (See
Table 1). Install seal flushing tube, if used. Install support
foot capscrews and tighten per torque chart (See Table 1).
Install coupler and align. Install drain plug, close drain
valve.
13. Install the Hex Coupler Guard as follows:
a. Spread the inner guard and place it over the coupler.
NOTE: Do not spread the inner and outer guards more
than necessary for guard installation. Over spreading
the guards may alter their fit and appearance.
b. With the inner guard straddling the support bracket,
install a cap screw through the hole in the support
bracket and guard located closest to the pump. Do not
tighten the capscrew.
c. Spread the outer guard and place it over the inner
guard.
d. Install the outer guard cap screws by following the step
stated below which pertains to your particular pump:
I) For pumps with a motor saddle support bracket:
Ensure the outer guard is straddling the support arm,
and install but do not tighten the two remaining cap
screws.
II) For pumps without a motor saddle support bracket:
Insert the spacer washer between the holes located
closest to the motor in the outer guard, and install
but do not tighten the two remaining cap screws.
e. Position the outer guard so it is centered around the
shaft, and so there is less than a 1/4" of shaft exposed.
f. Holding the guard in this position, tighten the three cap
screws.
14. Open isolation valves, inspect pump for leaks, if not leaking return pump to service.
1510-S Stuffing Box
With Special Single Mechanical Seal Figure 10 and 11

1510-D Stuffing Box


With Special Double Mechanical Seal Figure 10 and 12
5. Remove the impeller capscrew, lock washer and washer.
Remove the impeller.
6. Remove hex nuts from seal cap bolts and remove coverplate capscrews. Remove coverplate from bracket.
7. Remove seal assembly. Thoroughly clean and inspect
shaft sleeve, seal cap, and coverplate seal cavity, replace if
required.
8. Lubricate shaft sleeve, seal cap and coverplate cavity with
soapy water (do not use petroleum lubricant). Insert one
stationary seal and O-ring into seal cap and the other into
the coverplate.* Slide the seal cap onto the shaft. Replace
seal cap gasket.* Slide rotating portion of seal assembly
onto shaft sleeve.
9. Assemble coverplate to bracket, tighten capscrews per
torque chart (See Table 1). Assemble seal cap to coverplate, tighten hex nuts on seal cap bolts per torque chart
(See Table 1).
10. Go to Step 11 of 1510 Standard Mechanical Seal
Instructions.
*For 11/4" I.D. Seal both parts will be housed in the coverplate as
shown in Figure 12. Seal cap gasket is not used.

1510-8G
With Standard Mechanical Seal Figure 13
5. Remove the impeller nut and washer. Remove the impeller
and impeller key.
6. Remove spacer sleeve and two nuts holding the gland to
the stuffing box.
7. Pull the coverplate off the bearing frame assembly. Remove
the seal, sleeve and gland.
8. Thoroughly clean the shaft, shaft sleeve and the coverplate
seal cavity. Inspect for surface damage like pitting, corrosion, nicks or scratches.
9. Apply Dow Corning Silicone Rubber #732 or equal to the
shaft at sleeve location. Slide the shaft sleeve onto the
shaft and spin sleeve to distribute sealant. Wipe off excess.

5. Remove the impeller capscrew, lock washer and washer.


Remove the impeller.

10. Slide the seal gland (flat side towards the stuffing box) on
the shaft.

6. Remove hex nuts from seal cap bolts and remove coverplate capscrews. Remove coverplate from bracket.

11. Lubricate the outer surface of the shaft sleeve, interior of


the stuffing box and seal elastomer with soapy water (do
not use petroleum lubricant). Install the stationary element
and rotating assembly of the mechanical seal on the shaft
sleeve; being certain that the two wearing surfaces face
each other and rotating half of the seal is installed closest
to the impeller end.

7. Remove seal assembly. Thoroughly clean and inspect seal


sleeve and seal cap, replace if required.
8. Lubricate shaft sleeve and seal cap with soapy water (do
not use petroleum lubricant). Insert stationary seal with
O-ring into the seal cap and slide onto the shaft. Replace the
seal cap gasket. Slide rotating portion of the seal assembly
onto shaft sleeve and lock in place. For 11/4" I.D. seals, the
collar should be 113/32" from the impeller end of the shaft
sleeve. For 15/8" and 23/8" I.D. seals, the distance should be
11/4". (See Figure 11).

12. Install the seal spring and spring retainer onto the shaft
sleeve. Slide the coverplate onto the bearing frame.
13. Install spacer sleeve (over the shaft sleeve), impeller key,
impeller, washer and impeller nut, then tighten impeller nut
to 25-30 ft-lbs. Install and tighten the gland nuts evenly
against the stuffing box.
9

14. Inspect volute O ring for damage, replace if necessary.


Install O ring around coverplate seat. Slide the bearing
frame / coverplate assembly into the volute (coverplate
flush tube fitting must be to top). Install volute capscrews
and gradually tighten with a star pattern (prevents impeller
rub) to 25-30 ft-lbs. Install drain plug. Close drain valve.
15. Go to step 13 of 1510 Standard Mechanical Seal
Instructions.
1510-PF Stuffing Box
With Packing Figure 10
5. Remove the impeller capscrew, lock washer and washer.
Remove the impeller and impeller key.
6. Remove hex nuts from packing gland and remove coverplate capscrews. Remove coverplate from bracket.
7. Remove packing rings from the stuffing box.
8. Check condition of shaft sleeve and replace if scored or
otherwise damaged.
9. Insert two packing rings in the stuffing box followed by the
lantern ring and then the remaining two pieces of packing.
Make certain that the packing joints are staggered 90
degrees.
10. Install, but do not tighten the packing gland.
11. Install coverplate over the pump shaft, tighten capscrews
per torque chart (See Table 1).

NOTE ON PACKED PUMP OPERATION:


Before starting pump, back off packing gland nuts or screws
until gland is loose. Re-tighten with fingers until gland is just
snug against the first packing ring. Initially, water may run
freely from packing. This is normal and should be allowed to
continue for a period of time before further tightening of the
gland. Tighten gland nuts slowly and uniformly, one flat at a
time.
An adequate leakage rate is not one single value for all pumps
and installations, but is the amount required to provide adequate cooling and lubrication. The required leakage will be
largely influenced by operating pressure, fluid temperature,
shaft speed, etc.
For fluid temperatures in the range of 32 to 190F, average
leakage rates of 60 to 80 drops per minute are recommended.
However, each individual pump and installation will have
unique operating conditions that will result in broadly variable
leakage rate requirements.
At fluid operating temperatures near the upper limit of 190F,
the maximum temperature rise of the leakage is particularly
important. A packed pump should never operate with steam
forming at the gland. This necessarily limits the temperature
rise to a maximum of about 20F. If the formation of steam
persists at higher leakage rates, cooling water must be provided by means of an external supply, or a heat exchanger
used to cool the by-pass flush.

12. Tighten packing gland to compress packing, read note on


packed pump operation.
13. Go to step 11 of 1510 Standard Seal Instructions.

FIGURE 13
IMPELLER KEY
SPACER SLEEVE
SHAFT SLEEVE

FLUSH TUBE

GLAND

WEARING RING

VOLUTE

SHAFT

IMPELLER NUT

BEARING FRAME
SLINGER

IMPELLER

MECHANICAL SEAL

DRAIN PLUG

COVERPLATE
O-RING

8G STANDARD MECHANICAL SEAL CONSTRUCTION

10

OPTIONAL
CASING
WEAR RINGS

TABLE 1 TORQUE CHART


CAPSCREW TORQUE
(FOOT-POUND)
Capscrew
Type

Head
Marking

Capscrew Diameter
1/4

5/16

3/8

7/16

1/2

5/8

10

16

24

46

17

30

50

76

48

SAE Grade 1& 2

Stainless Steel

SAE Grade 5

DEALER SERVICING
If trouble occurs that cannot be rectified contact your local
representative. He will need the following information in order
to give you assistance.
1. Complete nameplate data of pump and motor.
2. Suction and discharge pipe pressure gauge readings.
3. Ampere draw of the motor.
4. A sketch of the pump hook-up and piping.

11

TUV

CERT
DIN ISO 9001

ISO 9001
Certified

Bell & Gossett


COPYRIGHT 1970, 1999 BY ITT INDUSTRIES, INC.
PRINTED IN U.S.A. 6-99

USA
Bell & Gossett
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: (847) 966-3700
Facsimile: (847) 966-9052
http://www.bellgossett.com

INTL.
Bell & Gossett / Export Dept.
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: (847) 966-3700
Facsimile: (847) 966-8366
Cable: BELGOSSETT

CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario,
N1H 1T1, Canada
Phone: (519) 821-1900