SPLIT-SYSTEM EVAPORATOR BLOWER (AIR COOLED) INSTALLATION INSTRUCTION Supersedes: Nothing N4C-0500

Transcription

1 SPLIT-SYSTEM EVAPORATOR BLOWER (AIR COOLED) INSTALLATION INSTRUCTION Supersedes: Nothing N4C-0500 MODEL L*BC GENERAL This 20 ton evaporator blower is designed with two distinct modules to provide maximum application flexibility. The units are shipped as single packages with the blower module mounted on top of the coil module, but the blower module can be repositioned in the field to meet almost any installation requirement. The blower module includes the blower wheels and room for a field--mounted motor and drive. The coil module includes direct expansion coils, 1" throwaway filters, liquid line solenoid valve for 50% capacity reduction, thermal expansion valves, distributors and a condensate drain pan. Each evaporator coil is pressurized with air to 325 psig and leak tested under water. After the headers are brazed onto the coil and the coil is installed in the unit, the coil will be pressurized with a combination of refrigerant--22 and nitrogen to 150 psig for pressure testing and additional leak testing. After the coil is evacuated and dehydrated, it will be pressurized with a holding charge of refrigerant--22 for storage and/or shipping. A supply air plenum, return air grille, steam coil, hot water coil, base section, suspension hardware, blower motors and drive accessories are available for field--installation to provide additional application flexibility. This evaporator blower, applied with a matching condensing unit, will provide years of quiet, efficient and dependable operation. PARTS Renewal Parts: Refer to Parts Manual for complete listing of replacement parts on this equipment. All forms referenced in this instruction may be ordered from: Standard Register 2101 West Tecumseh Road Norman, Oklahoma Toll Free Fax: (877) Toll Free Phone: (877) This instruction covers the installation and operation of the evaporator blower unit. For information on the installation and operation of the matching condensing unit, refer to Form N6Y. INSPECTION As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier's freight bill. A separate request for inspection by the carrier's agent should be made in writing. Installer should pay particular attention to the words: NOTE, CAUTION and WARNING. Notes are intended to clarify or make the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/or equipment damage may result if installation procedure is not handled properly.

2 TABLE OF CONTENTS General...1 Parts...1 Inspection...1 Nomenclature...2 INSTALLATION Limitations...3 Location...3 Rigging...3 Clearances...3 Foundations...3 Duct Connections Insulation...3 Supply Air Ducts...3 Return Air Duct Angles...3 Air Discharge Conversion...4 Capacity Reduction...7 Drain Connection...7 Blower Motor Mounting Location...7 Motor Arrangements...7 Refrigerant Mains...9 Installing Refrigerant Mains...9 Evaporator Section Piping...9 Air System Adjustment...10 Electrical Connections...10 Maintenance...12 TABLES No. Description Page 1 Unit Application Data Physical Data Operating Weight Distribution Accessory Operating Weight Distribution Accessory Static Resistance (IWG) Electrical Data Blower Motor and Drive Data Blower Performance FIGURES No. Description Page 1 Connecting Supply Ductwork Mounting Hardware Vertical & Horizontal Arrangement Plenum Base Accessories Unit Mounting Liquid Line Solenoid Valves Drain Piping Motor Mounting Location Motor Mounting Assembly Motor Arrangement Locations Motor Pulley Field Wiring Unit Dimensions PRODUCT CATEGORY L = Split-System Evaporator Blower PRODUCT NOMENCLATURE L D B C -N A NO MOTOR FACTORY INSTALLED HEAT A = Cooling only PRODUCT GENERATION D = 4th Generation PRODUCT IDENTIFIER BC = Evaporator Blower Unit NOMINAL COOLING CAPACITY 240 = 20 Tons 2 Unitary Products Group

3 LIMITATIONS This unit must be installed in accordance with all national and local safety codes. If no local codes apply, installation must conform with the appropriate national code. The unit is designed to meet National Safety Code Standards. If components are to be added to a unit to meet local codes, they are to be installed at the dealer's and/or the customer's expense. See Table 1 for unit application data. LOCATION The LEU240 evaporator blower is not designed for outdoor installation. It must be located within the building structure, either inside or outside the conditioned space. The unit should be located as close to the condensing unit as practical and positioned to minimize bends in the refrigerant piping. Units being installed vertically or horizontally can be set directly on a floor or platform, or they can be supported by metal or wooded beams. Units being installed horizontally can be suspended from above as shown in Figure 5. Refer to Form N7.1U for more information on the installation of the suspension accessory and for the individual load on each hanger rod. RIGGING INSTALLATION Care must be taken when moving the unit. Do not remove any packaging until the unit is near the place of installation. SPREADER BARS SHOULD BE USED BETWEEN THE SLINGS TO PREVENT CRUSHING THE UNIT FRAME OR PANELS. When preparing to move the unit, always determine the center of gravity of the unit in order to equally distribute the weight. Rig unit by attaching chain or cable slings around the bottom skid. A lift truck may be used to raise a unit to a sus- TABLE 1 - UNIT APPLICATION DATA pended location. Refer to Table 2 for the total unit operating weight. CLEARANCES A 24 inch clearance is required on the end with the piping connections and the supply air blower motor to properly service and maintain the unit and to replace the filters. Some clearance will also be require for the duct and power wire connections. A clearance equal to the unit width will be required on one end of the unit if the blower shaft or the evaporator coil will have to be replaced without moving the unit. FOUNDATIONS The evaporator blower may be suspended from joists with isolation--type hangers or hooks. Refer to Figures 2 and 5 and Tables 3 and 4. All units may be set directly on a floor, pedestal, platform shelf or mounted on the suspension accessory used as a base. DUCT CONNECTIONS Ductwork should always be suspended with hangers or supported by legs. It should never be fastened directly to the building structure. Allow clearance around ducts for safety in the handling of heated air and for insulation when required. INSULATION -- Ductwork insulation should: 1. Be used when ducts pass through an unconditioned space during the cooling season or through an unheated space during the heating season. Voltage Supply Air Range Entering Air Temperatures, F Power Variation CFM Supply Cooling-db/wb Heating-db Min. Max. Min. Max. Min. Max. Min. Max. 208/ /57 95/72-150* * Both hot water and steam coils. (Do NOT use steam in hot water coils) TABLE 2 - PHYSICAL DATA Evaporator Coil Rows Deep Rows High Finned Length (in.) Fins/Inch Tube OD (in.) Face Area (Sq. Ft.) Wheel Dia. x Wd.(in.) (2 Per Unit) Quan. & Size (in.) Face Area (Sq. Ft.) / Centrifugal Blowers 15 x 12 Filters (8) 20 x 22 x 1 (Throwaway) 24.1 Operating Charge (Refrigerant.-22) Lbs.-Oz Weight (Lbs.) Shipping* 800 Operating 690 Accessory Operating Weights (Lbs.) * Less Motor and Drive. Motor & Drive 3 HP 90 5 HP 120 Supply Air Plenum 150 Base 120 Return Air Grille 15 Steam Coil 1-Row Deep 150 Hot Water Coil 150 FIG. 1 - SUGGESTED METHOD FOR CONNECTING SUPPLY AIR DUCTWORK Unitary Products Group 3

4 2. Include a vapor barrier around the outside to prevent the absorption of moisture. 3. Be no less than 2 inches thick with weather proof coating when applied to ducts exposed to outdoor conditions. SUPPLY AIR DUCTS See Figure 1 for suggested method of connecting supply air ductwork. Non--flammable material collars should be used to minimize the transmission of noise and/or vibration. RETURN AIR DUCT ANGLES Return air duct angles are shipped turned in. They are intended to be unscrewed and turned for connection of duckwork. Discard these angles when the return air grille accessory is used. The return air grille accessory attaches in the same manner as the panels. The supply air plenums and bases that are shown in Figure 4 are shipped knocked--down. Separate assembly instructions are packed with these accessories. Form N8.2U --Supply Air Plenum Form N8.1U --Base AIR DISCHARGE CONVERSION Units are shipped for upflow operation, but may be converted for any of the illustrated air discharge patterns shown in Figure 3. Convert a follows: 1. Remove the panels from the blower section. 2. Remove Phillips machine screws located inside casing corner angles which hold coil and blower sections together. FIG. 2 - MOUNTING HARDWARE NOTE: Before proceeding to Step 4, see the section on Blower Motor Mounting Locations and mount the blower motor in the desired position. 4. If accessory heating coils are used, mount heating coil between coil and blower sections. Screw fastening locations are the same for all sections and heating accessories. If heating coils are not used, refasten coil section to blower section with machine screws removed in Step Before replacing panels, see Duct Connections and Drain Connections. 6. Replace panels. 3. Rotate blower section for the air discharge pattern desired. 4 Unitary Products Group

5 VERTICAL ARRANGEMENT HORIZONTAL ARRANGEMENT FIG. 3 - VERTICAL AND HORIZONTAL ARRANGEMENT SUPPLY AIR PLENUM DECORATIVE BASE FIG. 4 - PLENUM AND BASE ACCESSORIES Unitary Products Group 5

6 NOTE: The following illustration shows how the channels should be secured to the unit using the hardware provided with the suspension accessory. 1] The same channels can be used in either position. When used to support a vertical unit, these channels should be cut to match the bottom dimension of the evaporator coil section. 2] The location of the supply air plenum. 3] The suspension channels have two sets of mounting holes to accommodate horizontal units with or without a heating coil. On a horizontal unit without a heating coil, the suspension channels will extend 3 inches beyond both ends of the unit. 4] The same channels can be used to support a horizontal, floor-mounted unit from below. 5] After these bottom channels are cut per Not 1, a new hole will have to be drilled at the cut end if the unit is to be mounted on isolators. FIG. 5 - UNIT MOUNTING TABLE 3 - OPERATING WEIGH DISTRIBUTION (Lbs.) Model Blower Motor Support Point Designation Horizontal Installation Vertical Installation W1 W2 W3* W4 W5 W6* W1 W2 W3* W4 W5 W6* 3 HP LEU240 5 HP * Blower Motor End Of Unit. TABLE 4 - ACCESSORY OPERATING WEIGHT DISTRIBUTION 1 (Lbs.) Accessory Model LEU240 Base 2 20 Supply Air Plenum 25 Return Air Grille 5 3 Hot Water Coil 25 Steam Coil 1 Row 25 1 These weights should be added to each point load (W1 thru W6) on the above table. 2 This accessory can only be applied on units installed in the vertical position. 3 This weight should only be added to point loads W1, W2 and W3. 6 Unitary Products Group

7 CAPACITY REDUCTION The evaporator coils for these blower units are intertwined and are equipped with one liquid line solenoid valve for capacity. As the external controller (thermostat) becomes satisfied, the control circuit of the condensing unit will unload its compressor and will de--energize (close) the solenoid valve for capacity reduction. DRAIN CONNECTIONS All drain lines MUST be trapped and located so they will not be exposed to freezing temperatures. The evaporator blower has 7/8 inch OD steel condensate stub at each end of a singe drain pan. Both ends are closed with plastic caps. A plastic ell with clamps is provided. Attach the ell to the desired end and run a full size 7/8 inch drain line to the nearest drain facility. Seal the cap at the unused end with suitable mastic. 2 ) # * ) 2 4 ) , 4 ) 1 2 ) FIG. 8 - TYPICAL MOTOR MOUNTING ASSEMBLY AND MOTOR more detailed view of the motor mounting assembly (the mounting plate and the channels) with a motor. MOTOR ARRANGEMENTS The recommended motor location for each blower arrangement is as follows. Refer to Figure 10. FOR LOCATION A Install the motor and drive package. The motor mounting assembly is already in the correct position ) 2 5 FOR LOCATION D 1.Move the motor mounting plate to the other end of the mounting channels. Do not rotate the mounting plate.. ) ; , FIG RECOMMENDED DRAIN PIPING The 3 inch dimension must equal or exceed the negative static pressure developed by the supply air blowers. If it does not, the condensate will not drain properly and may overflow the drain pan. The trap must be at least 2 inches deep to maintain a water seal under all operating conditions, especially when the blowers are starting up. BLOWER MOTOR MOUNTING LOCATIONS The blower units are always shipped from the factory less motor and drive. The motor mounting assembly, however, is always factory--installed as shown in Figure 8. Figure 9 shows a 2.Install the motor and drive package. FOR ALL OTHER LOCATIONS 1.Move the entire motor mounting assembly (both the mounting plate and the channels) so that the mounting plate will be in the correct location. NOTE: The blower section must be lifted off the evaporator section to gain access to the mounting channel fasteners. Since these sections have to be repositioned for arrangements 2,3,5,6,7,9,10 and 12 of Figure 3, the motor mounting assembly should be relocated before the two sections are rejoined. FIG 7. - SHIPPING LOCATION FOR MOTOR MOUNTING ASSEMBLY Unitary Products Group 7

8 ARRANGEMENT 1, 4, 8, OR 11 ARRANGEMENT 2, 6 OR 7 ARRANGEMENT 3, 5 OR 10 ARRANGEMENT 9 OR 12 NOTE: Since the motor mounting assembly cannot be secured to the panel with the blower openings, the motor cannot be installed in any of the normally recommended bottom positions. FIG MOTOR ARRANGEMENT LOCATIONS NOTE: Shipping location for the motor mounting plate on the mounting channels. 8 Unitary Products Group

9 2.Rotate the motor mounting plate 180 degrees on the mounting channels.(for locations C,F,H, and J only! Do not rotate the plate for location D,E,G, or I.) 3.Install the motor and drive package. REFRIGERANT MAINS A majority of service troubles are caused by lack of adequate precautions to provide an internally clean and dry system. It is extremely important that all field--supplied materials conform with established standards. Hard drawn copper tubing should be used where no appreciable amount of bending around pipes or other obstructions is necessary. Use long radius ells wherever possible. If soft copper is used, care should be taken to avoid sharp bends which may cause a restriction. Where refrigerant lines pass through a wall, pack fiber glass insulation and a sealing material such as permagum around the refrigerant lines to reduce vibration and to retain some flexibility in the lines. The refrigerant lines should be supported by suitable hangers, brackets or clamps. Braze all copper to copper joints with Silfos--5 or equivalent brazing material. Do not use soft solder. Never braze or solder the liquid and suction lines together. The complete suction line should be insulated with no less than 1/2 inch ARMAFLEX or equivalent. If it is desirable to tape or wire the liquid and suction lines together for support purposes, they must be completely insulated from each other. INSTALLING REFRIGERANT MAINS The units are shipped with a holding charge of Refrigerant--22. The connections are terminated with a copper disc brazed over the ends. Before starting installation of the mains, be sure the unit has not developed a leak in transit by connecting a pressure gauge to the service access port. If pressure still exits, the circuit may be considered leak free. If pressure does not exist, the unit must be evacuate along with the field installed refrigerant piping. NOTE: To minimize the possibility of system failure due to dirt and moisture, a filter--drier must be installed in each liquid line as close to the evaporator as possible. Filter--dryers are not supplied with the evaporator blowers. They are supplied with the matching condensing units. The temperature required to make or break a brazed joint is sufficiently high to cause oxidation of the copper unless an inert atmosphere is provided. CAUTION: Dry nitrogen should flow through the system at all times when heat is being applied and until the joint has cooled. The liquid, suction and drain connections inside the unit must be piped to the outside. Refer to Unit Dimensions or the locations and the dimensions of the access openings in the unit panel. Copper liquid and suction line elbows and plastic drain elbow with hose clamps are shipped with the unit for field installation. The refrigerant piping and the condensate drain can be connected from either end of unit. The evaporator coil section is shipped with the side panels suitable for right hand piping connections when viewed from the return air end of the section. If left hand piping connections are required, the large and the small panels on the right side of the coil section can be interchanged with the single panel on the left side. The small panel has the holes for the refrigerant lines and the condensate drain line, and it is interchangeable for left hand or right hand piping connections. When left hand piping connections are installed, the suction line must be insulated to prevent moisture from condensing on it and being carried into the blower section. Grommets are supplied by the factory for field mounting in the holes provided in the narrow panel. These grommets are packed in the same carton with the other piping connections, and the carton is shipped in the unit's evaporator coil section. Remove the evaporator holding charge and any caps or discs on the liquid and suction connections that will not permit a free flow of nitrogen. CAUTION: After recovering the R--22 holding charge, use a small drill bit to puncture sealing caps and discs before unbrazing to prevent the pressure in the line from blowing them off. EVAPORATOR SECTION PIPING Connect a supply of dry nitrogen through a reducing regulator to an access valve or charging tail. Choose a procedure that will allow nitrogen to flow continuously through the system and reach all joints to be brazed. Begin the refrigerant mains by installing the liquid line from the condensing unit liquid stop valve to the evaporator liquid connection, maintaining a flow of nitrogen during all brazing operations. The filter--drier and sight glass must be located in this line, close to the evaporator. Make the suction line connection at the evaporator and run the line to the condensing unit. After puncturing the sealing caps with a small drill bit, unbraze the condensing unit suction disc and connect the line. Maintain a flow of nitrogen from the liquid valve access connection through the liquid line to the evaporator, through the evaporator, back to the condensing unit and out the suction valve access connection. CAUTION: The liquid line solenoid valves are shipped in the manually open position. After brazing is completed, close the valves by turning the stem clockwise. NOTE: Size the suction line outside the evaporator casing per the line sizing information provided in condensing unit instruction Form N6Y. EXPANSION VALVE BULB The bulb for the first stage TX valve on each of these blower units is not factory--installed in its final location; it's only temporarily taped for shipment. It must be fastened in a four o'clock position to the common suction line out of the evaporator coil after piping connections are made. Use the bulb clamps from the bag tape to the suction connection inside the blower unit. AIR SYSTEM ADJUSTMENT Unitary Products Group 9

10 Refer to Table 7 and 8 to adjust air system. TWIN BELT DRIVE ADJUSTMENT Check to see if both belts drive at the same speed. Do this by making a mark across both belts. Turn the drive several revolutions by hand. If mark hasn't separated, the belts are traveling at the same speed. Twin groove blower motor pulleys should be installed with the shaft set screw (A) towards the motor. See Figure 11. If necessary to align pulleys, the housing of the twin groove motor pulley may extend 25% of its length beyond end of motor shaft. TABLE 6 - ELECTRICAL DATA-SUPPLY AIR MOTOR Nominal HP Rating 3 5 Power Supply Name -plate Amps Locked Rotor Amps Min. Wire Size 1, AWG Based on three 60 deg. C, insulated copper conductors in steel conduit. 2 Based on an 80% power factor and a 3% voltage drop. Max. Wire Lg. 2, Feet Max. Fuse Size, Amps Always align twin groove pulleys using the stationary web. The blower motor pulleys are adjustable by half turns. Select required RPM from Table 7 and adjust pulley. Check belt tension. Drive packages are supplied with Fiberglass belts which must be properly tensioned at installation because they do not stretch. The belt should deflect 3/16 inch per foot of belt span with a 2 or 3--pound force. Alignment of the resilient motor mount can be corrected by adjustment at the slots on the end opposite the pulleys. 0! + - # " - 7 &! 2 0 ) ) / ; / 4 7, 7 /. 4 / 4 7, ,! 6 * +, * " 4 : ; * ; " 8, ), / * ;. 1-,! 2 0 ) ) / ; - 8 ) 2 4 ) 6 4 * ) NOTE: There are two (2) flats on the pulley head at 180 degrees against which the set screws may be tightened " / ) 8 ) ) : 4 + ; ; / ) " % " 0! + - " " - 7 "! 2 0 ) ) / ;, ), / * ;. 1-,! 2 0 ) ) / ; / 4 7, 7 /. 4 / 4 7, , , , 8 ) 8-5! +, * 6 * " 4 : ; * ; " 8-8 ) 2 4 ) 6 4 * ) " / ) 8 ) ) : 4 + ; ; / , ) ; 6 * ) 14 0 ), FIG DOUBLE GROOVE PULLEY ELECTRICAL CONNECTIONS Refer to matching condensing section wiring diagrams. Install a power supply to meet the requirements listed in Table 5. Refer to Figure 12 for typical field wiring. Provide a disconnect switch and fusing as required. Install interconnecting control wiring between condensing section, evaporator blower and room thermostat ) " % " FIG FIELD WIRING ) + + 4, ) ) + ) ), ) 6 1 ) ) +, , / ) / - + ) / ) / - + ) / TABLE 5 - ACCESSORY STATIC RESISTANCE, IWG CFM Supply Air Plenum Return Air Grille Non- Freeze Steam Coil Hot Water Coil Unitary Products Group

11 TABLE 7 - BLOWER MOTOR AND VARIABLE V-BELT DRIVE DATA (Factory Supplied) Drive Motor Blower Pulley Motor Pulley Package Belt Model No. RPM Range HP Frame Speed Shaft Size Mfg.. No. Size Mfg.. No. Size 1LD /8 A55 AK x 1-3/16 1VM x 7/8 1LD /8 A51* 2AK94 9 x 1-3/16 2VP x 1-1/8 * Two matched belts. All dimensions are in inches. They are subject to change without notice. Certified dimensions will be provided upon request. ACCESSORIES Heating Coil - Add 6 inches to overall height when used. Supply Air Plenum - Add 24-5/8 inch to overall height when used. Base - Add 23-3/8" to overall height when used A B C D E F G 89-1/ /8 29-1/2 2-7/16 2-7/ /8 H J K L M N P 12-7/ / /4 1 1/5/8 FIG UNIT DIMENSIONS Filters must be cleaned or replaced as often as necessary to assure good air flow and filtering action. 1.To remove filters through the sides of the unit, remove either the solid side panel on the piping end, or the larger side panel on the end opposite the piping. 2.To remove filters from the front of the unit, loosen two screws and raise the top filter retainer. The upper filters can be lifted over the center filter lip. Three wing nuts are provided under the center filter retainer. Remove these and a part of the center filter support, giving access to the bottom filters. On sections using the Return Air Grille, first remove the grille and then follow procedure for removing filters from front of unit. Drain pan(s) should be inspected regularly to assure proper drainage. MAINTENANCE The evaporator blower bearings and blower motor bearings are permanently lubricated. Unitary Products Group 11

12 TABLE 8 - BLOWER PERFORMANCE-AVAILABLE EXTERNAL STATIC PRESSURE-IWG FOR ACCESSORIES AND DUCT SYSTEM STATIC RESISTANCE (Allowance made for wet coil and filters) CFM RPM ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW ESP BHP KW Unitary Products Group 5005 York Drive, Norman, Oklahoma Subject to change without notice. Printed in U.S.A Copyright by York International Corporation 2002 All Rights Reserved. Supersedes: Nothing Code: SBC N4C-0500