Modular Packaged Unit Installation, Operation and Maintenance Manual Modular Packaged Cooling Unit FOR YOUR SAFETY FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. If you smell gas: 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flames. 4. Immediately call your gas supplier.
TABLE OF CONTENTS WARRANTY .................................................................................................................................................. 3 INSTALLATION ............................................................................................................................................. 4 Mechanical ................................................................................................................................................ 4 Site Preparation ....
WARRANTY This equipment is warranted to be free from defects in materials and workmanship, under normal use and service, for a period of 12 months from date of shipment. This warranty shall not apply if: 1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation instructions shipped with the product, 2. The equipment is not installed in accordance with federal, state and local codes and regulations, 3. The equipment is misused or neglected, 4.
INSTALLATION It is imperative that this unit is installed and operated with the designed airflow, gas, and electrical supply in accordance with this manual. If there are any questions about any items, please call the service department at 1-866-784-6900 for warranty and technical support issues.
Optional Moisture Eliminator Panel If the unit is equipped with an optional moisture eliminator panel, the maximum face velocity of the coil may be increased to 650 FPM. Moisture eliminator panels require minimal maintenance. Visual inspection is recommended periodically. Scale or clogging will impair performance. If scale or clogging occurs, remove the panel and flush with steam or water. Flushing should not have sufficient force to dislodge the media from the panel.
Typical Roof Mount Installation Typical Roof Mount Installation with Exhaust Fan 6
Plumbing Connections There is one field plumbing connection required for proper DX coil operation. This is the drain pan located under the DX coil. Depending on the size of the unit, the coil can generate 5 gallons of water per hour. It is imperative that the plumbing be sized accordingly. Also, it’s recommended that all plumbing connections be sealed with Teflon tape or pipe dope. Only 1” diameter PVC Pipe and low profile couplings should be used.
Copper Wire Ampacity 1. Always disconnect power before working on or near this unit. Lock and tag the disconnect switch or breaker Wire Size AWG Maximum Amps to prevent accidental power up. 14 15 2. This unit contains 2 or 3 disconnect switches and 12 20 multiple wiring connections. 1 disconnect is for the mua 10 30 blower. The second disconnect is used for units with 2 8 50 condensers. A third disconnect is added for units with 3 6 65 condensers.
MUA/Condenser Fan to Building Wiring Connection Single Phase Condenser: Condenser 1 is the Blue/Blue lines; Condenser 2 is the Red/Red lines; Condenser 3 is the Grey/Grey lines. Three Phase Condenser: Condenser 1 is the Blue/Blue/Blue lines; Condenser 2 is the Red/Red/Red lines; Condenser 3 is the Grey/Grey/Grey lines.
OPERATION Prior to starting up or operating this unit, check all fasteners for tightness. In particular, check the set screw in the wheel hub, bearings and the fan sheaves (pulleys). With power and/or gas OFF or prior to connecting ventilator to power, turn the fan wheel by hand to be sure it is not striking the inlet or any obstacles. Re-center if necessary. WARNING: GLOVES AND SAFTEY GLASSES MUST BE WORN WHEN SERVICING REFRIGERATION EQUIPMENT.
13. If the unit is a cooling only unit, adjust the air proving switch such that prevailing winds cannot start the condensers without the blower operating. With the unit operating, turn the adjustment screw clockwise until condensers stop operating. Then turn the adjustment screw counterclockwise until condensers operate. Turn the screw one half turn more counterclockwise. 14. Refer to the MUA manual to complete the startup of the MUA unit.
98°F – 83.5°F = 14.5°F of subcooling This should be compared to the condenser nameplate subcooling, which in this case is 14°F as shown to the right. As a reminder, to increase subcooling, add refrigerant charge and to decrease subcooling, remove refrigerant charge. R410A can be added to a system the same as previous R22 systems, such that it can be added as a liquid into the suction side if done slowly to allow the refrigerant to evaporate before entering the compressor.
If the superheat is too low, and an adjustable-type valve is supplied, the superheat can be increased by turning the adjustment stem in a clockwise direction. It's a good practice to wait for 15 to 20 minutes after adjusting the valve, to allow for the system to balance out before determining the effect of the adjustment. If the superheat is too high, it can be lowered by turning the stem in a counter-clockwise direction. To adjust the superheat, first remove the bottom cap from the TXV.
Sequence of Operation-Cooling with Direct, Indirect, or Electric Heat This unit is most easily understood when broken down into smaller individual systems. There are two main systems, a make-up air (MUA) fan and a cooling system. The make-up air fan consists of a blower and motor. The cooling system consists of a condenser(s), DX coil, filter/dryer, and thermal expansion valve. Basic cooling units include 2 thermostats for proper operation.
Sequence of Operation-Reheat The unit can be equipped with an optional reheat coil downstream from the DX coil. When this option is installed, warm, liquid refrigerant will flow through a reheat coil before it enters the DX coil. This warms the cooled air discharged from the DX coil and helps to lower the relative humidity of the airstream. Reheat is always activated in this system, and only uses refrigerant from stage 1.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • Space Cool SP – Stage 1 space cooling set point. Space Cool SP #2 – Stage 2 space cooling set point. Space Cool SP #3 – Stage 3 space cooling set point. Space Heat SP – Stage 1 space heating set point. Space Heat SP #2 – Stage 2 space heating set point. Space Heat SP #3 – Stage 3 space heating set point. Outdoor Cool SP – Stage 1 outdoor cooling set point. Outdoor Cool SP #2 – Stage 2 outdoor cooling set point.
• Clear Faults – Once the faults have been resolved, choosing this option will wipe them from the board’s memory. If the fault has not been resolved, it could re-appear on the view faults screen. • • • • • • RTU Y1 – Option to enable or disable Y1 (stage 1) output. RTU Y2 – Option to enable or disable Y2 (stage 2) output. RTU Y3 – Option to enable or disable Y3 (stage 3) output. RTU O/B – Option to enable or disable O/B output.
Board Menu 18
Components The following image outlines the typical modular packaged unit components. Systems are available with heating modules, mixing boxes and 1, 2 or 3 condensers.
Troubleshooting The following tables list causes and corrective actions for possible problems with the units. Review these lists prior to consulting manufacturer.
MAINTENANCE To guarantee trouble free operation of this unit, the manufacturer suggests following these guidelines. Most problems associated with fan failures are directly related to poor service and maintenance. Please record any maintenance or service performed on this fan in the documentation section located at the end of this manual.
2. Filters need to be cleaned and/or replaced quarterly, and more often in severe conditions. Washable filters can be washed in warm soapy water. When re-installing filters, be sure to install with the airflow in the correct direction as indicated on the filter. 3. Check for and remove debris that has settled around the base of the condenser. This will ensure proper water drainage from the condenser. Yearly 1. 2. 3. 4. Inspect bearings for wear and deterioration. Replace if necessary.
Start-Up and Maintenance Documentation START-UP AND MEASUREMENTS SHOULD BE PERFORMED AFTER THE SYSTEM HAS BEEN AIR BALANCED AND WITH THE COOLING ON (Warranty will be void without completion of this form). Job Information Job Name Address City State Zip Phone Number Fax Number Contact Purchase Date Service Company Address City State Zip Phone Number Fax Number Contact Start-Up Date Unit Information Refer to the start-up procedure in this manual to complete this section.
Maintenance Record Date Service Performed Factory Service Department Phone: 1-866-784-6900 Fax: 1-919-554-9374 24
