Johnson Controls ENVIRO-TEC MQL B Series User manual

BY JOHNSONCONTROLS
MODEL MQL SERIES B
INDOOR AIR HANDLING UNIT
INSTALLATION, OPERATION
& MAINTENANCE Supersedes: ET102.19-NOM1 (1012) Form ET102.19-NOM1 (813)
Issue Date:
August 26, 2013

This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced mate-
rials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
JOHNSON CONTROLS
2
FORM ET102.19-NOM1
ISSUE DATE:08/26/2013

The equipment covered by this manual is designed for
safe and reliable operation when installed and operated
within its design specification limits. To avoid person-
al injury or damage to equipment or property while
installing or operating this equipment, it is essential
that qualified, experienced personnel perform these
functions using good judgment and safe practices. See
the following cautionary statements.
ELECTRICAL SHOCK HAZARDS.
All power must be disconnected prior to
installation and serving this equipment.
More than one source of power may be
present. Disconnect all power sources
to avoid electrocution or shock injuries.
MOVING PARTS HAZARDS. Motor
and Blower must be disconnected prior
to opening access panels. Motors can
start automatically, disconnect all power
and control circuits prior to servicing to
avoid serious crushing or dismember-
ment injuries.
HOT PARTS HAZARDS. Electric Resis-
tance heating elements must be discon-
nected prior to servicing. Electric Heaters
may start automatically, disconnect all
power and control circuits prior to servic-
ing to avoid burns.
SAFETY CONSIDERATIONS
WARNING
Failure to follow these instructions could result in death, serious
injury or equipment damage
Follow all warnings and instructions in the unit's Manual(s).
1. Follow all applicable regulations and safety practices during rigging and lifting.
2. Prepare and follow written rigging and lifting plan.
3. Lifting must be directed by trained professional rigger.
4. Spreader bars must be used and be long enough to prevent rigging from contacting
unit.
5. Use all and only designated lift points according to unit's Manual(s).
6. Locate center of gravity through trial lifts to account for possible variations in unit
configuration.
7. Use rigging and lifting techniques that keep unit stable and level.
8. Keep clear of unit when lifted.
JOHNSON CONTROLS 3
FORM ET102.19-NOM1
ISSUE DATE:08/26/2013

CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically to
the manual owner. Updated manuals, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current litera-
ture is available from the owner of the equipment prior
to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
Check that the unit assembly and compo-
nent weights can be safely supported by
rigging and lifting equipment.
All assemblies must be adequately se-
cured during lifting and rigging by
temporary supports and restraints until
equipment is permanently fastened and
set in its nal location.
All unit temporary and permanent sup-
ports must be capable of safely sup-
porting the equipment’s weight and any
additional live or dead loads that may
be encountered. All supports must be
designed to meet applicable local codes
and ordinances.
All fastening devices must be designed
to mechanically lock the assembly in
place without the capability of loosening
or breaking away due to system opera-
tion and vibration, vibration, impact or
seismic events.
Secure all dampers when servicing
damper, actuator or linkages. Dampers
may activate automatically, disconnect
control circuits or pneumatic control
systems to avoid injury.
Protect adjacent flammable materials
when brazing, Use ame and heat pro-
tection barriers where needed. Have re
extinguisher available and ready for im-
mediate use.
JOHNSON CONTROLS
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FORM ET102.19-NOM1
ISSUE DATE:08/26/2013

TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................9
Inspection .........................................................................................................................................................9
Introduction.......................................................................................................................................................9
General....................................................................................................................................................9
Unit Identification..............................................................................................................................................9
Hand Identification............................................................................................................................................ 9
Rigging And Handling....................................................................................................................................... 9
Storage...........................................................................................................................................................10
Assembling Equipment................................................................................................................................... 11
Gasketing .............................................................................................................................................. 11
Mounting Actuator ................................................................................................................................ 11
Mixing Box............................................................................................................................................. 11
SECTION 2 - INSTALLATION ................................................................................................................................13
Installation .....................................................................................................................................................13
Suspended Units ...................................................................................................................................13
Suspending Using Factory Base Rail ............................................................................................13
Suspending Using Field Supplied Supports...................................................................................15
Internal Isolation ....................................................................................................................................15
External Isolation ..................................................................................................................................15
Service Clearance .................................................................................................................................15
Panel Removal...............................................................................................................................15
General Piping.......................................................................................................................................15
DX Connection Steps .....................................................................................................................................16
In the eld:.............................................................................................................................................16
Notes:.............................................................................................................................................16
Condensate Drain .................................................................................................................................16
Electrical Installation..............................................................................................................................16
INSPECTION & START-UP CHECKLIST .............................................................................................17
SECTION 3 - STARTUP..........................................................................................................................................19
Electric Heat Start-Up.....................................................................................................................................19
Before Start-Up Check ...................................................................................................................................19
Start-Up ..........................................................................................................................................................19
First Time Motor Startup.................................................................................................................................20
Air Balancing .........................................................................................................................................20
Sheaves .........................................................................................................................................20
SECTION 4 - PERIODIC MANINTENANCE AND SERVICE .................................................................................21
PERIODIC MAINTENANCE AND SERVICE..................................................................................................21
General..................................................................................................................................................21
After 48 Hours of Operation ..................................................................................................................21
Weekly...................................................................................................................................................21
Every Month ..........................................................................................................................................21
Every Three to Six Months ....................................................................................................................21
JOHNSON CONTROLS 5
FORM ET102.19-NOM1
ISSUE DATE:08/26/2013

TABLE OF CONTENTS (CONT’D)
Every Year .............................................................................................................................................21
Drain Pan ..............................................................................................................................................22
Inspecting and Cleaning Drain Pans..............................................................................................22
Air Filters ...............................................................................................................................................22
Throwaway Filters..........................................................................................................................22
Fans ......................................................................................................................................................22
Inspecting and Cleaning Fans .......................................................................................................22
Fan Bearings .........................................................................................................................................23
Bearing Set Screw Alignment ........................................................................................................23
Lubricating the Fan Bearing ..................................................................................................................23
Motor .....................................................................................................................................................23
General Inspection.........................................................................................................................23
Lubrication and Bearings ...............................................................................................................24
Types of Grease.............................................................................................................................24
Lubrication Procedure....................................................................................................................24
With Grease Outlet Plug ................................................................................................................24
Without Grease Outlet Plug ...........................................................................................................24
Drives ....................................................................................................................................................25
Mounting Straight Bore Sheaves ...................................................................................................25
Mounting Split Tapper Sheaves .....................................................................................................26
Adjust Variable Pitched Sheaves ...................................................................................................26
Belts ......................................................................................................................................................27
Adjusting Belt Tension....................................................................................................................27
How to Increase Belt Life ..............................................................................................................27
Coils ......................................................................................................................................................28
Steam, Hot Water and Chilled Water Coils ....................................................................................28
Refrigerant Coils ............................................................................................................................29
Winterizing Water Coils .........................................................................................................................29
OPERATING GUIDELINES............................................................................................................................29
Operating Limits ....................................................................................................................................29
Vibration Levels.....................................................................................................................................29
Vibration Causes ...................................................................................................................................30
Periodic Service and Maintenance........................................................................................................30
APPLICATION RECOMMENDATION FOR COILS........................................................................................30
General..................................................................................................................................................30
Water Cooling Coils...............................................................................................................................30
Direct Expansion Coils ..........................................................................................................................30
Steam Coils ...........................................................................................................................................31
Water Heating Coils...............................................................................................................................32
SECTION 5 - TROUBLESHOOTING......................................................................................................................33
JOHNSON CONTROLS
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FORM ET102.19-NOM1
ISSUE DATE:08/26/2013
TABLE OF CONTENTS

LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - Lifting Unit With Base Rails ...................................................................................................................9
FIGURE 2 - Lifting Units Without Base Rails...........................................................................................................10
FIGURE 3 - Assembly, Units Without Base Rails .................................................................................................... 11
FIGURE 4 - Assembly, Units With Base Rails ......................................................................................................... 11
FIGURE 5 - Gasket Application ............................................................................................................................... 11
FIGURE 6 - Suspended Units .................................................................................................................................12
FIGURE 7 - Hand Identication...............................................................................................................................13
FIGURE 8 - Remove Hold Downs...........................................................................................................................14
FIGURE 9 - Isolator Installation...............................................................................................................................14
FIGURE 10 - Drain Trap..........................................................................................................................................15
FIGURE 11 - Mounting Sheaves .............................................................................................................................21
FIGURE 12 - Sheave Alignment..............................................................................................................................22
FIGURE 13 - Split Tapper Sheave Mounting...........................................................................................................22
FIGURE 14 - Belt Tension .......................................................................................................................................23
TABLE 1 - Minimum Hex Head Bolt Torque In Lb-Ft - Grade 5 Bolt .......................................................................18
TABLE 2 - Recommended Greasing Intervals Of Fan Bearings.............................................................................19
TABLE 3 - Recommended Greases For Various Operating Ranges ......................................................................20
TABLE 4 - Fan Bearing Maximum Grease Capacity...............................................................................................20
TABLE 5 - Recommended Motor Greasing Schedule ............................................................................................21
TABLE 6 - Determining Deflection Force ................................................................................................................25
TABLE 7 - Forward Curve Fan Data .......................................................................................................................26
TABLE 8 - Vibration Levels .....................................................................................................................................26
TABLE 9 - MQL Troubleshooting Analysis ..............................................................................................................29
TABLE OF CONTENTS (CONT’D)
JOHNSON CONTROLS 7
LIST OF FIGURES
FORM ET102.19-NOM1
ISSUE DATE:08/26/2013

THIS PAGE INTENTIONALLY LEFT BLANK.
JOHNSON CONTROLS
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FORM ET102.19-NOM1
ISSUE DATE:08/26/2013
LIST OF FIGURES

INSPECTION
Upon receipt of equipment, carefully check all items
against the bill of lading to ensure that all equipment
has been received. Note any discrepancy on the bill of
lading before signing.
Inspect all equipment for any signs of damage caused
during transit. Note any visual damage on the bill of
lading before signing. Immediately report all visual
and concealed damage to the carrier and file a claim.
INTRODUCTION
General
In order to ensure long and trouble free life, the
equipment should have proper care and maintenance.
Enough space should be left around the unit for service
and repair, see .Installation on page 13
Equipment, as shipped, is factory assembled as far
as job specifications and shipping limitations allow.
Where field assembly is required, bolts, nuts, screws
and gasketing material are provided with each module.
Modules bolt together from the inside of the upstream
module.
UNIT IDENTIFICATION
To ensure the assembled MQL modules are in the
proper sequence, each module has an identifying code
and an airflow direction label. The proper assembly
sequence is listed on the supply fan nametag. The first
listed module is the first section in the direction of air-
flow.
HAND IDENTIFICATION
Coil connections and other components are located
and described as left or right hand. The proper orienta-
tion to describe the proper hand is when airflow is at
your back. Vertical stacked top sections maintain the
same handling as lower section. See Figure 7 on page
14
RIGGING AND HANDLING
The MQL air handler can ship as separate modules,
fully assembled, or in separately assembled sections
depending on the unit size and application. The equip-
ment must be rigged as it was shipped from the factory.
Do not remove shipping skid or protective cover until
equipment is ready for final placement, as damage to
equipment can result. Do not remove protective caps
from piping connections until ready to connect piping.
FIGURE 1 - LIFT POINTS FOR UNITS WITH BASE RAILS
JOHNSON CONTROLS 9
FORM ET102.19-NOM1
ISSUE DATE:08/26/2013
1
SECTION 1 - INTRODUCTION

Units with base rails can be rigged by means of lift-
ing holes on the end of base rail (see Figure 1 on page
9).
Units without base rails must be lifted with slings.
Place slings at ends and joints of modules to prevent
damage to equipment (see Figure 2 on page 10).
Spreader bars must be used to prevent damage to equip-
ment. Avoid twisting or uneven lifting of equipment.
Do not lift equipment by coil connection or headers.
See submittal drawings.
If transporting units with forklift, forks must extend the
full width of unit to prevent damage to bottom of unit.
Always take special care when handling the blower
module. All fans are dynamically balanced. Rough
handling may cause bearing misalignment and/or shaft
damage.
STORAGE
To transfer equipment from truck to storage site, refer
to Rigging And Handling on page 9
If a forklift is used, lift only from heavy
end of skid.
1. Do not stack unit modules or accessories during
storage. Stacking can cause damage or deforma-
tion.
2. If equipment is to be stored for more than two
weeks prior to installation, observe the following
precautions:
a. Choose a dry storage site that is reasonably
level and sturdy to prevent undue stress or
permanent damage to the equipment struc-
ture or components. Do not store equipment
on vibrating surface. Damage to station-
ary bearings can occur. Set equipment off
ground if in moisture prone areas.
FIGURE 2 - LIFT POINTS FOR UNITS WITH BASE RAILS
JOHNSON CONTROLS
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FORM ET102.19-NOM1
ISSUE DATE:08/26/2013
SECTION 1 - INTRODUCTION