Daikin OAH 003G Manual

Installation and Maintenance Manual IM 777-7
Skyline™ Air Handler Group: Applied Air Systems
Part Number: IM 777
Date: November 2011
© 2011 Daikin
Models OAC/OAH 003G – 090G

2Daikin IM 777-7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Curb Mounting and Unit Leveling . . . . . . . . . . . . . . . 5
Assembling Sections . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shipping Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panels, Frame Channels, and Doors . . . . . . . . . . . . . 8
Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Frame Channel Removal . . . . . . . . . . . . . . . . . . . . . . 8
Access Doors and Panels . . . . . . . . . . . . . . . . . . . . . 8
Fan Section Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Injected-Foam Insulated Panels . . . . . . . . . . . . . . . . . 9
Field Mounting Junction Boxes and
Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dampers and Hoods . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Face and Bypass Section Mounting . . . . . . . . . . . . 11
Isolation Dampers for Multiple Fans . . . . . . . . . . . . 11
Piping Vestibules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piping and Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Water Cooling Coils . . . . . . . . . . . . . . . . . . . . . . . . . 11
Direct Expansion Coils . . . . . . . . . . . . . . . . . . . . . . . 12
Steam Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Heating Coils . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drain Pan Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Internal Isolation Assembly Adjustment . . . . . . . . . 15
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 19
Startup Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Before Starting the Unit . . . . . . . . . . . . . . . . . . . . . . 19
VFD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . 20
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fan Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . 24
Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service and Maintenance . . . . . . . . . . . . . . . . . . . . 25
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . 25
Ball Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . 25
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VM and VP Variable Pitch Key Type Sheaves . . . . 26
LVP Variable Speed Sheaves . . . . . . . . . . . . . . . . . 27
MVP Variable Speed Sheaves . . . . . . . . . . . . . . . . 28
Fan Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . 30
Front Load Filter Option . . . . . . . . . . . . . . . . . . . . . 31
Filter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Winterizing Water Coils . . . . . . . . . . . . . . . . . . . . . . 32
Removing and Replacing Components . . . . . . . . . 32
Removing the Fan Section . . . . . . . . . . . . . . . . . . . 32
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Service and Warranty Procedure . . . . . . . . . . . . . . 36
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Warranty Return Material Procedure . . . . . . . . . . . 36
Check, Test, and Start Procedure Form . . . . . . . . . 37
Quality Assurance Survey Report . . . . . . . . . . . . . 39

Daikin IM 777-7 3
Introduction
Introduction
General Information
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.
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.
Receiving and Handling
1Carefully check items against the bills of lading to verify
all crates and cartons have been received. Carefully
inspect all units for shipping damage. Report damage
immediately to the carrier and file a claim.
2Skyline 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.
3Take special care when handling the blower section. All
fans are dynamically balanced before leaving the factory.
Rough handling can cause misalignment or a damaged
bearings or shaft. Carefully inspect fans and shaft before
unit installation to verify this has not happened.
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.
Nomenclature
CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.
2AH 003 G D A C
Model
OAH = Custom modular air handler
OAC = Custom modular component
Nominal unit size
(cataloged size—nominal square foot of coil)
003, 004, 006, 008, 010, 012, 014, 017,
021, 025, 030, 035, 040, 050, 065, 080, 085, 090
Vintage of Daikin air handling unit
Unit cross section
C = Standard unit cross section
M = Custom size cross section
Motor location
A = Motor along side of fan housing
D = Motor down stream of belt drive
plenum fan
F = Motor on inline fan
G = Motor downstream of direct drive
plenum fan
H = Motor downstream of fan array
T = Motor behind twin fan housing
Unit type/coil position
B = Blow-through cooling coil location
D = Draw-through cooling coil location
H = Heating only
V = Vent only
M = Multizone

4Daikin IM 777-7
Introduction
Unit Storage
•Store on a level surface in a clean, dry location where
temperature can be controlled if possible.
•Pack fan and motor bearings (unless motor bearings are
sealed) with compatible grease with the shaft stationary.
After grease has been installed, rotate shaft about 10
rotations.
•Isolate unit from shock and vibration.
•Once a month, rotate shaft a minimum of 10 revolutions.
Insure the stopped position is different than the original
position.
•Coat shafts with lubricant as needed to prevent corrosion.
•A descant bag may be hung in the interior of the unit to
minimize corrosion in humid storage environments.
•Do not clean galvanized steel surfaces with oil dissolving
chemicals. This may remove the protective coating and
accelerate corrosion.
•Do not allow coverings to trap moisture on galvanized
surfaces.
Belt driven fans:
•Reduce belt tension by at least 50% or remove the belts.
Remove belts if they will be subjected to temperatures
exceeding 85° F to avoid deterioration.
• Remove belt guard when adjusting belts
• Reduce belt tension prior to removing or installing belts.
Removing or installing tensioned belts may cause per-
sonal injury and damage to the sheaves, belts, bearings or
shafts.
•Adjustable sheaves should be opened as wide as possible
and the adjustment threads lubricated so they do not corrode.
Be careful not to put lubricant on the belt running surface
Prior to start up:
•Set screws on bearings, fan wheels, and sheaves need to be
checked for proper torque. Also check bolt torque for any
taper lock hubs either on the wheel or sheaves.
•Check sheaves for corrosion. Significant corrosion can cause
belt or sheave failure.
•Purge old grease from fan bearings while rotating the shaft
to distribute the new grease evenly and prevent bearing seal
failure.
•Correctly align and tension belts. See General Rules of
Tensioning‚ page 30.

Daikin IM 777-7 5
Mechanical Installation
Mechanic al Installation
Service Clearances
In addition to providing adequate space around the unit for
piping coils and drains, access to at least one side of the unit is
always required to allow for regular service and routine
maintenance, which includes filter replacement, drain pan
inspection and cleaning, fan bearing lubrication, and belt
adjustment. Provide sufficient space—at least equal to the
length of the coil—on the side of the unit for coil removal. See
Figure 1 for servicing space requirements.
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). Fan sections
with multiple fans have motor control boxes up to 16” deep
when supplied with VFDs.
Figure 1: Servicing Space Requirements
Figure 2: Service Clearance for Electrical Power Devices
Rigging
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.
Figure 3: Unit and Section Rigging
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 Daikin representative or visit
www.DaikinApplied.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).
4 . 0 0 " b e r l e x t e n o n
W d t h
3 0 . 0 0 " 4 . 0 0 " W d t h o f c o l e c t o n
W d t h o f
f n e c t o n
3 0 . 0 0 "
H e g h t
54"
12"

6Daikin IM 777-7
Mechanical Installation
If the unit is supported on rails they must be placed around the
entire perimeter. Additional Supports must be placed
perpendicular to airflow spanning the full width of the unit at
all shipping splits. If the unit is over 107” wide these supports
must also be placed at the entering and leaving edges of fan
and cooling coil sections. The perimeter rails must be at least
2” wide at the top and capable of carrying the entire weight of
the unit. The cross supports must be 4” wide at the top and
capable of carrying the weight of the two sections it spans. The
cross supports shall be placed such that 2” of the top is
supporting each section. The perimeter rails shall be placed so
that they are fully supporting the outer 2” of the unit. If shims
are required they must be placed such that the unit is fully
supported.
Figure 4: Leveling the Unit
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 9). For Skyline Plus units, ensure that
the D-gasket is attached to the entering air side frame channel
(Figure 7 and Figure 10).If it dislodged during shipping,
restore it to its designed position.
Shipping Sections
1Caulk all assembly joints of the unit—Before 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
2Pull 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.
3Fasten base rails together first using the 3/8"-16 × 5"
bolts located in the splice kit provided with the unit
(Figure 7).
aTo 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.
bIf 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.
cHandle 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
Figure 7: Fasten Bottom of Section
S h m t o p r e e n t
d t o r t o n f w d t h
o e r 1 0 8 "
S h m e c t o n u n t l
t h e y r e t r g h t
n d l e e l
1 / 4 " d m e t e r
b e d c e n t e r e d
n f c e o f
c l e r n c e
U e S p l c e
J o n t
g u d e
R e m o b l e
L f t n g B r c k e t
3/8" x 1" Bolt and Nut
“D”
Gasket

Daikin IM 777-7 7
Mechanical Installation
dA length of “D” gasket is attached to each section
(Figure 7). This gasket MUST be installed to the unit
base section.
eHandle 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.
fFor certain Skyline Plus units, use the provided
section joining plates to fasten sections together.
Space them as shown in Figure 8. Using the provided
¼"-14 x 1" self tapping screws, drill screw the joining
plates into the frame channel on each section, keeping
unit sections tight together. Follow instruction
drawing included in the assembly kit.
Figure 8: Frame Channel Stiffener Plates (Skyline Plus
Units Only)
Figure 9: Internal Fastening
Figure 10: D-Gasket Placement Detail (Skyline Plus Units
Only)
1Check that the sealant is compressed between the mating
channels when the unit sections are joined. Touch up any
places where gaps are noted.
2After 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 11).
3Assemble the small splice plate at the top rail to secure
the sections together at the top. Use 5/16" bolts
(Figure 11).
Figure 11: Splice Cap and Splice Plate
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.
V e w A
A
S p l c e C o l l r
m u t b e l g n e d
t o e l t o g k e t .
5/16-18 N ut S p l c e
P l t e
5 / 1 6 - 1 8 B o l t
S l d e S p l c e C p o n
nd bend end dow n

8Daikin IM 777-7
Mechanical Installation
Panels, Frame Channels, and Doors
Panel Removal
To remove a side or top panel, remove the flat head Torx 30
fasteners along the sides of the panel. Lift off the panel after
removing all fasteners.
Frame Channel Removal
Frame channels that run the length of the unit along the top can
be removed to allow access to both the side and top of the unit.
To remove the frame channel, first remove the side panel(s).
Once the side panel is off, remove the flat head Torx 30
fasteners in the corner of the frame channels. Then pull the
frame channel out the side. Remove any panel screws that are
within one inch of the of the frame since they are engaged into
the gasketed flange of the frame (Figure 12).
Figure 12: Removing Panel Screws
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.
Fan Section Doors
Note: Opening fan section doors requires using a 1/2" socket
wrench (Figure 13), which satisfies ANSI standards and
other codes that require the “use of tools” to access
compartments containing moving parts or electrical
wiring.
1Insert 1/2" socket and rotate 1/4 turn clockwise as shown in
Figure 13. If the handle is on the left side of the door, rotate
1/4 turn counterclockwise.
2Rotate the door handle 1/4 turn clockwise and then 1/4 turn
counterclockwise to release any internal pressure or
vacuum and open the door. If the handle is on the left side
of the door, rotate the door handle 1/4 turn
counterclockwise and then 1/4 turn clockwise.
3To prevent air leakage, tighten the door panels by adjusting
the jam nuts.
Figure 13: Opening Fan Section Door
Remove panel
to remove frame
Remove any
panel screws that
engage frame
CAUTION
Sharp edges and coil surfaces are a potential injury hazard.
Avoid contact with them.
ATTENTION
Les bords tranchants et les surfaces des bobines sont un
risque de blessure. Ne les touchez pas.

Daikin IM 777-7 9
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.
Panel Cutting Procedure
1Determine the number and location of holes required for
electrical conduit, piping, and control wiring as follows:
aCheck that adequate space is available inside the unit
for conduit or pipe routing.
bDo not locate holes in a panel that provides access to
key maintenance components such as filters and fan
assemblies.
cDo not locate where the conduit or piping blocks
airflow or obstructs hinged access doors.
2Once 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.
3Seal 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.
Figure 14: Cutting/Sealing Injected-Foam Insulated Panels
Field Mounting Junction Boxes and
Other Components
For field mounting 4" × 4" or smaller junction boxes to the
standard panel exterior, use a minimum quantity of four, 3/16"
diameter pop rivets. Do not use self-tapping drill screws.
They will not tighten nor secure properly and panel
damage can occur.
If larger, heavier components require mounting on unit panels,
use through-bolts with flat washers through both outer and
inner panels. To maintain panel integrity, seal both ends with
an industrial/commercial grade silicone sealant or duct seal
compound.
The unit frame channel is another excellent location for
securing heavier components; self-tapping screws are not
acceptable. Ensure that the location permits the full operation
of all access doors and panels and does not interfere with other
vital components.
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 15).
Figure 15: Discharge Plenum
WARNING
Flame and smoke can cause equipment
damage, severe personal injury, or death.
Before operating unit, seal all piping and
wiring holes on both inner and outer panels
with an industrial grade silicone sealant or
duct seal compound. Do not use a cutting
torch or expose panel to fire. Panel
damage can occur.
WARNING
La fumée et les flammes peuvent
endommager le matériel et causesr des
blessures graves ou la mort.
Avant d’utiliser le dispositif, obturer tous les
trous de passage de tubulures et de fils
ménagés dans les panneaux intérieurs et
extérieurs au moyen d’une pâte à base de
silicone ou d’un mastic d’étanchéite â
conduits de qualité industrielle.
Ne pas se servir d’un chalumeau coupeur ni
exposer les pannequx à une flamme nue
pour ne pas risquer de les endommager.
Cut hole from both sides of panel
Seal completely with silicone
sealant or duct seal compound
Prop 65—Substances in fuel or from fuel combustion can cause personal injury or death,
and are known to the State of California to cause cancer, birth defects or other reproductive harm.
D c h r g e
P l e n u m

10 Daikin IM 777-7
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 16).
Figure 16: Flashing Over Top Panels and Sides of Units
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 17).
Figure 17: Filler Panel Over the Weather Hood
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 18).
Figure 18: Field-Installed Barrier Between Hoods
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.
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.
F l h n g
D u c t
F l h n g U n t t o p
p n e l
F l h n g
D u c t
F l h n g
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 l’arbre est de 205po/lb. Une plus grande rotation
(ou torque) peut endommager l’équipement.
E x h u t
I n t k e
B r r e r