INSTALLATION IN STRUC TION

Transcription

1 INSTALLATION IN STRUC TION MODELS FCHP090 & /60 Hz SPLIT-SYSTEM HEAT PUMPS INDOOR UNITS Su per sedes: N2W (692) N2W (194) GEN ERAL These com pletely as sem bled in door units in clude a wellinsulated cabi net, a cop per tube/alu mi num fin coil, throw - away fil ters, a cen trifu gal blower, a blower mo tor, an ad just - able V- belt drive, a blower mo tor con tac tor and a small hold ing charge of refrigerant- 22. They also in clude a filterdrier, an ex pan sion valve and a dis tribu tor that are only used dur ing the cool ing cy cle plus A check valve to pro vide the proper flow of re frig er ant through the coil dur ing both the cool ing and heat ing cy cles. Supplemental resistance heaters, a sup ply air ple num, a return air grille and a base are avail able as ac ces so ries for field instal - lation. The units are shipped in the vertical position ready for field in - stallation. For horizontal installation, reverse the solid bottom panel and the return air duct flange on the front of the unit. REF ER ENCE This in struc tion covers the installation of the indoor unit. For in - for ma tion on the installation and operation of the matching out - door unit, ref er to Form N1W. Re newal Parts:? Refer to Parts Manual for com plete listing of re place ment parts on this equipment. All forms ref er enced in this instruction may be or dered from: Publications Distribution Center Unitary Products Group P.O. Box 1592, York, Pa Installer should pay par ticu lar attention to the words: NOTE, CAUTION and WARNING. Notes are intended to clarify or make the installation eas ier. Cau tions are given to pre vent equipment dam age. Warnings are given to alert the installer that personal injury and/or equip ment damage may re sult if the installation procedure is not han dled properly. IN SPEC TION As soon as a unit is re ceived, it should be in spected for pos si - ble damage during tran sit. If damage is evident, the extent of the damage should be noted on the carrier's freight bill. A sepa - CAUTION THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL, STATE, AND NATIONAL CODES INCLUDING, BUT NOT LIMITED TO, BUILDING, ELECTRICAL, AND MECHANICAL CODES. WARNING INCORRECT INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR ADDITIONAL INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER

2 N2W GENERAL... 1 REFERENCE... 1 INSPECTION... 1 NOMENCLATURE... 2 INSTALLATION LIMITATIONS... 3 LOCATION... 3 RIG GING... 3 CLEARANCES... 3 VERTICAL/HORIZONTAL INSTALLATION... 5 DUCT CONNECTIONS... 5 REFRIGERANT MAINS... 6 DRAIN CONNECTION... 6 SUPPLY AIR BLOWER ADJUSTMENT... 7 POWER AND CONTROL WIRING TABLE OF CONTENTS FIGURES Figure No. Description Page 1 Unit Suspension Mount ing Vertical & Horizontal Application Electric Heater Accessory Supply Air Plenum Accessory Base Accessory Return Air Grille Accessory Recommended Drain Piping Motor Mounting Assembly Hole Locations for Pressure Drop Pressure Drop vs Supply Air CFM Field Wiring Unit Dimensions & Clearances Refer to the matching outdoor unit installation instruction (Form N1W) for the operating sequence of the entire system. MAINTENANCE INDOOR COIL DRAIN PAN FILTERS LUBRICATION BELTS TABLES Table No. Description Page 1 Physical Data Application Data Blower Motor Pulley Adjustment Blower Performance (60Hz Units) Blower Performance (50Hz Units) Accessory Static Resistance Blower Motor & Drive Data Electrical Data... 9 PRODUCT NOMENCLATURE F C H P - S A PRODUCT CATEGORY F = Split-System Heat Pump Indoor Unit FACTORY INSTALLED HEAT A = No Heat Installed PRODUCT GENERATION C = 3rd Generation PRODUCT IDENTIFIER HP = In door Unit VOLTAGE CODE -S = 208/230/ K = 380/ NOMINAL COOLING CAPACITY (@ 60 Hz) 090 = 7-1/2 Ton 120 = 10 Ton 2 Unitary Products Group

3 rate re quest for inspection by the carrier's agent should be made in writing. LIMI TATIONS These units must be installed in ac cor dance with all national and lo cal safety codes. If no lo cal codes ap ply, installation must con form with the ap pro pri ate national codes. Units are de - signed to meet National Safety Code Stan dards. If components are to be added to a unit to meet lo cal codes, they are to be in - stalled at the dealer's and/or the cus tomer's ex pense. See Ta - ble 2 for application limitations. LO CA TION These indoor units are not de signed for outdoor installation. They must be located within the building structure, either in side or outside the con di tioned space. INSTALLATION WARNING: Be careful when attaching the hanger rods. Use a washer with a back-up nut on each rod and tighten down against the cabi net so they will not be al - lowed to turn or slip. RIG GING AND HAN DLING N2W Ex er cise care when moving the unit. Do not remove any pack - aging until the unit is near the place of installation. The packaging consists of a bottom wooden skid that can be lifted with a fork truck from any di rec tion, a card board container that cov ers the en tire unit, and strap ping that se cures the card - board container to the bottom skid. These units can be rigged with slings under the bottom skid. The units should be lo cated as close to the outdoor units as practical and po si tioned to minimize bends in the refrigerant pip ing. Units being installed vertically or horizontally can be set directly on a floor or platform, or they can be sup ported by metal or wooden beams. Units be ing in stalled hori zon tally can be sus pended from above. Four 3/8" weld nuts are pro vided in the unit frame to ac - com mo date hanger rods. Knockouts must be re moved from the unit pan els to expose these weld nuts. Ref er to Fig ure 1 for their location and the in di vid ual load on each hanger rod. CAU TION: Spreader bars should be used to prevent the slings from crushing the unit panels and frame. Bef ore rig ging any unit, determine its weight from Ta ble 1. Bef - ore rig ging a unit for horizontal installation, determine its cen ter of gravity from Figure 1, and make sure that its weight will be dis trib uted equally. CLEAR ANCES All units re quire certain minimum clearances for proper opera - tion and serv ice. Refer to Figure 12 for these clear ances. TABLE 1 - PHYSICAL DATA DESCRIPTION UNIT MODEL FCHP090 FCHP120 Rows Deep x Rows High 3 x 24 3 x 32 Finned Length - inches Coil Face Area - square feet Tube (Copper) OD - inches 3/8 3/8 Fins (Aluminum) per inch Centrifugal Blower (Forward Curve) Diameter x Width - inches 15 X X 15 Blower Motor 1 Nominal Rating - HP 1-1/2 2 Filters (Throwaway) Quantity Per Unit - 16" x 25" x 1" 4 4 Total Face Area - square feet Refrigerant-22 (Lbs.) 2 Holding Charge - - Pumpdown Capacity Unit Weight (lbs.) Shipping Operating KW Electric Heat ers 16 KW KW Accessory Operating Weights (Lbs.) 36 KW Supply Air Plenum Base Return Air Grille All of these 1750 RPM motors have a solid base, a 56 frame, a 1.15 service factor, inherent protection & permanently lubricated ball bearings. Refer to page 6 for additional motor & drive data. 2 Refer to Form N1 for system charge. Unitary Products Group 3

4 N2W TABLE 2 - APPLICATION DATA Model FCHP090 FCHP120 Power Sup ply 208/ / / / Utili za tion Range A in ac cor dance with ARI Stan dard 110. Voltage Varia tion 1 Entering Air Temperatures,?F Supply Air CFM Cooling - wb Heating - db Min. Max. Min. Max. Min. Max. Min. Max. 2 The system amy op er ate below 50?F for a short pe ri od of time when warm ing up the conditioned space after a long shutdown Model Accessory Based on a Standard Blower Motor Center of Gravity Weight Dimensions, In. Distribution, Lbs. A B W1 W2 W3 W4 Total Basic Unit Only 25-5/8 23-1/ FHP090 Unit with Electric Heat 30-3/4 23-3/ Unit with Plenum 35-1/8 23-1/ Unit with Electric Heat & Plenum / Basic Unit Only 24-1/8 23-1/ FHP120 Unit with Electric Heat 29-1/4 23-3/ Unit with Plenum 33-3/8 23-1/ Unit with Electric Heat & Plenum 36-5/8 23-5/ NOTE: Unit weights (with electric heat ac ces sory) are based on an av er age heater weight of 68 lbs. FIG. 1 - UNIT SUSPENSION MOUNTING (Horizontal Application) 4 Unitary Products Group

5 WARNING: Do not per mit over hang ing struc tures or shrubs to ob struct air discharge. Additional height may be re quired for snow clear ance if win ter op era tion is expected N2W The return air duct flange is factory- mounted on the front of the unit, but it can be reversed with the solid bottom panel for hori - zontal ap pli ca tions. A sup ply air ple num (Fig. 4), a bas (Fig. 5) and a return air grille (Fig. 6) are avail able as field-installed accessories, and one of the fol low ing respective in struc tions will be packed with each. FIG. 3 - ELECTRIC HEATER ACCESSORY (Vertical Arrangement Shown) FIG. 2 - VERTICAL AND HORIZONTAL VERTICAL / HORI ZON TAL INSTALLATION These indoor units are shipped for vertical installation with ver - tical air discharge as shown in Fig ure 2(A) but may be con - verted for horizontal installation as shown in Fig ure 2(B) by interchanging the solid bottom panel and the return air duct flange. DUCT CON NEC TIONS Design and install all ducts in accordance with all national and/or lo cal codes. FIG. 4 - SUPPLY AIR PLENUM ACCESSORY (Vertical Arrangement Shown) Ducts should be sized no smaller than the duct flanges on the unit or the elec tric heater (if used). Ref er to the unit dimensions (Fig. 12) and the heater detail (Fig. 3) for these sizes. Ref er to Form N10.1 for installation in struc tions on the elec tric heater. Use flexible fiber glass or plastic cloth col lars or other non flam - mable material at the unit duct connections to minimize the trans mis sion of noise and vi bra tion. In su late all ductwork run ning through un con di tioned ar eas to prevent moisture condensation and to provide more eco nomi - cal operation. FIG. 5 - BASE ACCESSORY (For Vertical Arrangement Shown) Unitary Products Group 5

6 N2W Refer to the installation instruction (Form N1) for the matching outdoor unit for piping limitations, line sizes, and other de sign considerations. INSTALLING REFRIGERANT MAINS The units are evacu ated and de hy drated at the factory and shipped with a holding charge of Refrigerant-22. The vapor and liquid connections are sealed with copper discs. WARNING: Pro vi sions for re cov er ing re frig er ant re leases must be avail able during all phases of installation, leak testing and charg ing. Do NOT release refrig - er ant into the at mos phere. FIG. 6 - RETURN AIR GRILLE ACCESSORY (Vertical Arrangement Shown) Form N10.2 Supply Air Plenum Form N10.3 Return Air Grille Form N10.4 Base The sup ply air ple num and the return air grille should be used in lieu of ductwork only when a free blow/free re turn application is practical. RE FRIG ER ANT MAINS Many serv ice problems can be avoided by taking ade quate pre cau tions to pro vide an internally clean and dry system and by using pro ce dures and ma te ri als that conform with estab - lished standards. Use hard drawn copper tubing where no appreciable amount of bend ing around pipes or other ob struc tions is nec es sary. Use long ra dius ells wher ever possible with one ex cep tion - small radius ells for any traps in a va por riser. If soft cop per is used, care should be taken to avoid sharp bends which may cause a re stric tion. Fi ber glass insulation and a sealing ma te rial such as perma - gum should be packed around refrigerant lines where they pene trate a wall to reduce vibration and to retain some flexibil - ity. If the unit has already lost its holding charge, it should be leak tested and the nec es sary repairs should be made. If the unit has maintained its holding charge, you can assume that it has no leaks and pro ceed with the installation. The tem pera ture re quired to make or break a brazed joint is sufficiently high to cause oxi da tion of the copper un less an in ert atmosphere is provided. Make sure the refrigerant in the lines has been re cov ered, then drill a small hole through the discs to pre vent any in ter nal pres - sure from blowing them off and to al low the flow of dry nitrogen through the connections when un braz ing the closures. The liquid and vapor connections must be piped outside the unit. Refer to the unit drawing for the lo ca tions and the di men - sions of these connections. Bef ore brazing the refrigerant lines to these connections, re - move the short panel from the unit frame and slide the grom - mets onto the refrigerant lines. After the brazed joints have cooled, slide the grommets back into place and se cure the panel to the unit frame. NOTE: These coils can only be piped from one side of the unit. DRAIN CON NEC TION Sup port all re frig er ant lines at minimum in ter vals with suitable hang ers, brackets or clamps. Braze all copper to copper joints with Sil-Fos 5 or equiva lent braz ing material. DO NOT USE SOFT SOLDER. Never braze or solder the liquid and vapor lines to gether. The complete vapor line should be in su lated with mini mum 1/2" AR - MAFLEX or equiva lent. If it is de sir able to tape or wire these lines together for support purposes, they must be com pletely in su lated, one from the other. FIG. 7 - RECOMMENDED DRAIN PIPING 6 Unitary Products Group

7 The drain line MUST be trapped because the coil is lo cated on the nega tive side of the sup ply air blower, and it must be pro - tected from freezing temperatures. A 7/8" OD drain con nec tion extends through right hand side of cabi net. Ref er to Fig. 7 for recommended drain pip ing N2W 3. The tension on the belt should be adjusted for a deflection of 3/16 of an inch per foot of belt span with an applied force of 2 to 3 pounds. This ad just ment is made by moving the blower mo tor mounting plate. Refer to Figure 8. Turning the ad just ment bolt (B) moves the motor mounting plate up or down. The drain con nec tion is lo cated on the same side of the unit as the refrigerant connections. The line should be in su lated where mois ture drippage will be objectionable or cause damage to the area. The 3" di men sion must equal or exceed the nega tive static pres sure de vel oped by the sup ply air blower. If it does not, the con den sate will not drain prop erly and may over flow the drain pan. The trap must be at least 2-1/2" deep to maintain a wa ter seal under all operating conditions, especially during blower TABLE 3 - SUPPLY AIR BLOWER MOTOR PULLEY ADJUSTMENT MODEL TURNS OPEN* FHP090 FHP090 FHP120 FHP Hz 50 Hz 60 Hz 50 Hz RPM 542 RPM 700RPM 581 RPM *Pulleys can be adjusted in half-turn increments. start-up. NOTE: The unit may have to be raised off the floor to al low enough height for the trap. SUP PLY AIR BLOWER AD JUST MENT The RPM of the sup ply air blower will de pend on the required CFM, the unit ac ces so ries and the static resistances of both the sup ply and the return air duct sys tems. With this information, the RPM for the sup ply air blower can be determined from the blower per form ance in Ta ble 4. Know ing the required blower RPM and the blower motor HP, the set ting (turns open) for the sup ply air mo tor pul ley can be determined from Ta ble 3. Each motor pul ley has: 1. A threaded bar rel with two flats (or notched recesses) 180 de grees apart. 2. A movable flange with one set screw. After the mov able flange has been rotated to the proper number of turns open, the set screw should be tightened against the flat on the barrel to lock the mov able flange in place. If the pul ley includes a locking collar, the locking collar must be loosened to ad just the set ting of the movable flange. Note the following: 1. The sup ply air CFM must be within the limitations shown in Ta ble All pul leys can be adjusted in half turn increments. FIG. 8 - TYPICAL MOTOR MOUNTING ASSEMBLY NOTE: Never loosen the two nuts (C). Two hex nuts (A) have to be loosened to move the mount - ing plate and re tight ened af ter the mounting plate has been moved to the proper position. 4. All pul leys are factory aligned. 5. All sup ply air mo tor pulleys are factory set 3 turns open. After the sup ply air blower mo tor is operating, ad just the re sis - tances in both the sup ply and the return duct systems to bal - ance the air distribution throughout the conditioned space. The job specifications may require that this bal anc ing be done by someone other than the equip ment installer. To check the sup ply air CFM after the ini tial bal anc ing has been com pleted: 1. Drill two 5/16 inch holes in the side panel as shown in Fig - ure In sert at least 6" of 1/4 inch tubing into each of these holes for suf fi cient pene tra tion into the air flow on both sides of the in door coil. NOTE: The tubes must be in serted and held in a position perpendicular to the air flow so that ve loc ity pres - sure will not af fect the static pres sure readings. 3. Us ing an in clined manometer, determine the pres sure drop across a dry indoor coil. Since mois ture on the coil may vary greatly, meas ur ing the pres sure drop across a wet coil un der field con di tions would be inaccurate. To as sure a dry coil, the heat pump system should be de-activated while the test is being run. 4. Know ing the pres sure drop across a dry coil, the actual CFM through the unit can be de ter mined from the curve in Fig ure 10. Unitary Products Group 7

8 N2W FIG. 9 - HOLE LOCATIONS FOR PRESSURE DROP READINGS FIG PRESSURE DROP ACROSS A DRY INDOOR COIL VS. SUPPLY AIR CFM TABLE 4 - SUPPLY AIR BLOWER PERFORMANCE 1,3 1 (60 Hz Units) RPM ESP 2 CFM BHP KW ESP 2 BHP KW ESP 2 BHP KW ESP 2 BHP KW ESP 2 BHP KW FCHP090 (60 Hz) FCHP120 (60 Hz) TABLE 5 - SUPPLY AIR BLOWER PERFORMANCE 1,3 (50 Hz Units) RPM ESP 2 CFM BHP KW ESP 2 BHP KW ESP 2 BHP KW ESP 2 BHP KW ESP 2 BHP KW FCHP090 (50 Hz) FCHP120 (50 Hz) Unit resistance is based on a wet indoor coil and clean filters. 2 Available static pressure in IWG to overcome the resistance of the duct system and any ac cessories added to the unit. Ref er to the Ta bles 5 & 6 for the resistance of these accessories and for additional motor and drive data. NOTE: Ref er to Form AD1 for blower per form ance curves. 3 Mo tors can be selected to op er ate into the serv ice factor because they are lo cated in the mov ing air stream, up stream of any heating de vice. 8 Unitary Products Group

9 TABLE 6 - ACCESSORY STATIC RESISTANCE (IWG)(To be in cluded with Duct System Static Resistance) Model Accessory Static Resistance, IWG N2W BLOWER CFM FHP090 Elec tric Heat 10 KW KW KW KW Supply Air Ple num Return Air Grille BLOWER CFM FHP120 Elec tric Heat 10 KW KW KW KW Supply Air Ple num Return Air Grille TABLE 7 - BLOWER MOTOR AND DRIVE DATA 60 Hz 50 Hz Adjustable Motor Pulley Fixed Blower Pulley Belt Model Motor HP* Blower RPM Pitch Dia. Bore Pitch Dia. Bore Pitch Lg. Designation (Inches) (Inches) (Inches) (Inches) (Inches) FHP / FHP /8 1 A FHP / FHP *These factory- mounted motors are wired for a 460V power sup ply. Refer to the wir ing dia gram in side the motor ter mi nal box when re con nect ing the mo tor leads for a 208 or 230 volt power sup ply. TABLE 8 - ELECTRICAL DATA Blower Mo tor HP 1-1/2 2 Power Sup ply FLA Max. Fuse Size, 1 AMPS Max. Wire Length 2 (Ft.) FCHP FCHP NOTE: Refer to Form N10.1 for electrical data on units equipped with an elec tric heat accessory. 1 Dual element, time de lay fuses. 2 Based on three 60?C, 14 AWG, insulated copper con duc tors in steel con duit, a 3% volt age drop. CONTROL WIRE SIZ ING Maximum Total Wire Size Circuit Length (Feet) #19 Solid 130 #18 Solid 170 #18 Stranded 180 #16 Stranded 270 #14 Stranded 455 #12 Stranded 730 To de ter mine the total circuit length, add the following distances: 1 - Outdoor Unit to Indoor Unit 2 - In door Unit to Thermostat 3 - Thermostat to Indoor Unit 4 - In door Unit to Outdoor Unit 5 - Outdoor Unit to Elec. Heater To tal Cir cuit Length Unitary Products Group 9

10 N2W If the CFM is above or below the speci fied value, the sup ply air mo tor pul ley may have to be readjusted. Af ter one hour of op - eration, check the belt and pulleys for tightness and align ment. WARNING: Failure to prop erly adjust the total system CFM can re sult in ex ten sive blower dam age. After readings have been obtained, remove the tubes and seal up the drilled holes in the side panel. Dot plugs (5/16" - P/N ) are avail able through nor mal parts or der ing proce - dures. through the 7/8" hole in the rear panel, and con nect them to the terminals on block 4TB. Refer to the unit drawing in Fig. 12 for the lo ca tions of these knockouts. If the unit in cludes an elec tric heat accessory, route the power wires into heater control box in lieu of the unit. Ref er to electric heat in struc tion Form N10.1 for ad di tional installation in for ma tion. NOTE: Shut down the heat pump system bef ore taking any test measurements to as sure a dry indoor coil. POWER AND CONTROL WIR ING Install electrical wiring in accordance with the latest National Electrical Code (NFPA Standard No. 70) and/or lo cal regula - tions. The unit should be grounded in ac cor dance with these codes. Route the power wires into the unit through the1-3/8" knockout Refer to Ta ble 7 to size the dis con nect switch, the power wir ing, the fuses and the control wir ing. Ref er to Fig. 11 for field wiring dia gram. Manual Changeover - 6TH Automatic Changover - 6TH FIG FIELD WIRING in the rear panel, and connect them to the ter mi nals on blower mo tor contactor 10M. Route the control wires into the unit 10 Unitary Products Group

11 N2W All dimensions are in inches. They are subject to change without notice. Certified dimensions will be provided upon request. AC CES SO RIES? ELEC TRIC HEATER - Add 14-1/4" to unit height when used.? SUP PLY AIR PLE NUM - Add 27-1/2" to unit height when used.? BASE - Add 20" to unit height when used. CLEAR ANCES Side with RETURN AIR opening 24" Side with SUPPLY AIR opening 24" 1 Side with PIPING CONNECTIONS 52" 2 Side opposite PIPING CONNECTIONS 12" Side with access for both POWER & CONTROL WIRING 3 Bottom 4 1 Overall dimension of the unit will vary if an electric heater, a supply air plenum or a base is used. 2 This dimension is required for removal of the coil. Only 26" is required for normal servicing. 3 Although no clearance is required for service and operation, some clearance may be required for routing the power wiring and the control wiring. 4 Allow enough clearance to trap the condensate drain line. FIG.12 - UNIT DIMENSIONS & CLEARANCES (FHP090 & 120) Unitary Products Group 11

12 SECURE OWNER'S APPROVAL: When the system is functioning properly, secure the owner's approval. Show him the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit, how to adjust temperature settings within the limitations of the system, how the defrost cycle is controlled and how the anti-cycle timer operates. NOTE: Motors are wired for a 460V power sup ply. Ref er to the wir ing dia gram in side the motor terminal box when re - IN DOOR COIL Do not allow dirt to accumulate on the in door coil or other parts of the sup ply/re turn air cir cuit. Clean as often as nec es sary to as sure good sys tem per form ance. Use a brush, vac uum cleaner attachment or other suitable means. If the coil be comes ex tremely dirty, it may be nec es sary to use an industrial grade detergent and a hose to clean the finned sur - faces. This is rec om mended to pre vent any loss in capacity and efficiency. DRAIN PAN The condensate drain pan should be in spected regularly to as - sure proper drain age. con nect ing mo tor leads for a 208 or 230 volt power supply. MAINTENANCE FIL TERS The filters must be re placed as of ten as nec es sary to as sure good air flow and fil ter ing ac tion. Clean filters will prevent any loss in capacity and efficiency. Refer to the unit drawing in Fig. 12 for the location of the fil ter access panel. LU BRI CA TION The bearings for the blower shaft and the blower motor are per - manently lu bri cated and should not require any ad di tional lu bri - cant. BELTS Maintain belt tension to ex tend belt life. Re place when signs of failure be gin to appear. Cen tral En vi ron men tal Sys tems Post Of fice Box 1592 York Penn syl va nia Sub ject to change without notice. Printed in U.S.A Copy right? by York In ter na tional Cor po ra tion 1994 All rights re served. Codes: SBF,L N2W