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I/O MANUAL Horizontal/Modular/Vertical/Rooftop AHU 2015pg

COMMERCIAL AIRE PRODUCTS 501 Terminal Road, Fort Worth TX 76106

Tel: 817-624-0820

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR AHU

HORIZONTAL, MODULAR, VERTICAL AND ROOFTOP UNITS

SIZES FROM 600 CFM TO 9,000 CFM

SIZES FROM 600 TO 4,000 CFM

SIZES FROM 600 CFM TO 9,000 CFM

Summary of Contents for AHU

Page 1: ...MERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR AHU HORIZONTAL MODULAR VERTICAL AND ROOFTOP UNITS SIZES FROM 600 CFM TO 9 000 CFM SIZES FROM 600 TO 4 000 CFM SIZES FROM 600 CFM TO 9 000 CFM ...

Page 2: ... the Unit 6 Lifting and Handling the Unit 6 Electrical 7 Cutting Electrical Openings 9 Start up List for duct Heaters 10 Minimum Air Flow Required Across the Heaters 11 Electrical Duct Heater Maintenance guide 12 Duct connections 13 Condensate drain Piping 14 Heating Coils Piping 14 Chilled Water Coils Piping 15 DX Coils Piping 16 Prior to Start Up 17 Operation and Maintenance 21 Limited Warranty ...

Page 3: ...ge is carrier responsibility Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements If repairs must be made to damaged goods then the factory should be notified before any repair action is taken in order to protect the warranty Certain equipment alteration repair and manipulation of equipment without the manufacturer s consent ma...

Page 4: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 4 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 5: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 5 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 6: ...o support the unit and reduce noise and vibration from the unit Allow adequate service clearances as shown on the unit nameplate and unit drawing Consult your local building codes for additional service clearance requirements Allow adequate space for piping access and panel removal Condenser water piping and condensate drain connections are located on either side of the unit Suspended Units Horizo...

Page 7: ...ng units are designed for upflow applications only ELECTRICAL Verify the unit nameplate agrees with the power supply The wiring diagram is located inside the unit Route the power and control wiring separately through the utility entry in the unit DO NOT RUN POWER AND CONTROL WIRES IN THE SAME CONDUIT ELECTRIC SHOCK HAZARD Before attempting to perform any installation service or maintenance shut of...

Page 8: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 8 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 9: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 9 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 10: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 10 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 11: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 11 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 12: ...ate the placement of the hole Be sure that the hole will not interfere with any component operation or prevent access to any part of the unit 2 Drill a pilot hole all the way through the panel insulation and interior panel 3 Using a hole saw cut the hole through the outside metal insulation and inside metal 4 Install the conduit through the panel and caulk the entire perimeter of the conduit in bo...

Page 13: ...90A and 90B 7 Locate the heater so that it is completely accessible and normal ventilation is assured 8 The amount of air curtain between the heater elements and limit switches must not be reduced by internal duct liner within 1 ft before or after the heater In fiber glass duct systems a metal sleeve inside the duct to support the heater must be used If the base of the heater is not flush with the...

Page 14: ...r if there is low or uneven air flow over the heating elements Air flow volume and or reinstallation of heater must be done before energizing heater 10 If heater has a control transformer it may have a breaker in the circuit If transformer is shorted breaker will open the circuit You must reset and find the cause of the short If transformer has no breaker it may have an inline fuse A short circuit...

Page 15: ...han one disconnect switch that needs to be in the off position 2 All electrical connections to the heater power control circuits should be tight Inspect all electrical connections in heater as they may become loose during operation All wiring must be done in accordance with the National Electrical Codes and any applicable state local codes 3 All air filters in duct or unit system should be checked...

Page 16: ...e gauge for proper operation of heater 13 Preventative maintenance to achieve maximum performance and service life of heater a formal schedule of regular maintenance should be established and maintained DUCT CONNECTIONS Check existing duct insulation and vapor barriers Previously installed heating supply ductwork may already have adequate insulation against excessive heat loss This insulation may ...

Page 17: ...ing water is on the leaving air side of the coil Coils must be adequately vented in order to prevent air binding Units are provided with manual air vents mounted through manifold panel Our units can have from two to 8 rows chilled water coils or any combination with pre heat and or reheat coils up to 10 rows factory mounted All control valves flow measuring devices and freeze controls are field su...

Page 18: ...ely couple the tubing to the indoor unit to avoid exposing the coils to moisture When making solder connections make sure to have dry nitrogen flowing through the lines to prevent copper oxidation inside the pipes Minimizing the refrigerant line size is favorable from an economic perspective reducing installation costs and reducing the potential for leakage However as pipe diameters narrow pressur...

Page 19: ... moisture in the line The sight glass should not be used to determine if the system is properly charged Use temperature and pressure measurements to determine liquid sub cooling not the sight glass Liquid Line Routing Care should be taken with vertical risers When the system is shut down gravity will pull liquid down the vertical column and back to the condenser when it is below the evaporator Thi...

Page 20: ...tion riser A double suction riser is designed to return oil at minimum load while not incurring excessive frictional losses at full load A double suction riser consists of a small diameter riser in parallel with a larger diameter riser and a trap at the base of the large riser At minimum capacity refrigerant velocity is not sufficient to carry oil up both risers and it collects in the trap effecti...

Page 21: ...e system The drain leg must be vertical its diameter should be the same as the diameter of the riser and it should be 1 foot long Install a sight glass in the drain leg for observation Run an oil return line using 1 8 inch capillary tube 10 feet in length from the drain leg to the suction line Connect the oil return line below the sight glass and 1 inch above the bottom of the drain leg HGB valves...

Page 22: ...e motor junction box can reverse single phase motor rotation refer to motor data plate Ensure all filters are properly installed and free from construction debris Replace all doors panels etc and check amperage draw of the motor The amperage draw should not exceed the nameplate amps shown on the motor data plate OPERATION AND MAINTENANCE WARNING Disconnect electrical power to all circuits before s...

Page 23: ...on the motor shaft and not on the fan shaft How They Work The two halves of an adjustable sheave As the two sections of an adjustable sheave are turned closer to each other the belt is forced to the outside of the sheave This requires the belt to have to travel a greater distance around the sheave This increases the speed of the fan and then the opposite would be true too yeah If we unscrewed the ...

Page 24: ... tables The two pieces of an adjustable sheave side by side 2 Measure the outside diameter of the belt riding on the sheave Also measure the physical outside diameter of the sheave just to be sure it is large enough to adjust to the required diameter Let s use this example You have a 3 adjustable motor sheave and the fan delivers 2300 cfm on a system that demands 3000 cfm Here is the formula with ...

Page 25: ...osed position Do not open more than five full turns for A belts or six full turns for B belts c Replace external key E and tighten set screw Y over key and set screw C into keyway in fixed half of the sheave Wrench torque 110 in lbs min 130 in lbs max d Verify sheave alignment install belts and adjust belt tension Do not force belts over grooves e Future adjustments should be made by loosening the...

Page 26: ...I O MANUAL Horizontal Modular Vertical Rooftop AHU 2015pg 26 COMMERCIAL AIRE PRODUCTS 501 Terminal Road Fort Worth TX 76106 Tel 817 624 0820 ...

Page 27: ... balance and verification of the final installation conditions Failure to do that can cause blow off water from the coils and damage to the equipment and system due to excessive face velocity over the cooling coils The motor sheave is adjustable to allow some RPM field change if major variation is needed consult factory for the proper sheave pulley combination MOTOR Tighten motor mount bracket and...

Page 28: ...es resulting from operation with inadequate supply of air or water 9 Damages resulting from use of components or accessories not manufactured or approved by Commercial Aire 10 Increase in fuel or electric cost This warranty is in lieu of all other warranties expressed or implied including the implied warranties of merchantability and fitness for a particular purpose Some states do not allow the di...

Page 29: ...ss doors and removable panels YES ___ NO ___ 5 Have all the shipping braces and protections been removed YES ___ NO ___ 6 Did you check the incoming voltage against the name plate YES ___ NO ___ 7 Have all electrical connections been tested YES ___ NO ___ 8 Has over current protection been installed matching the requirements YES ___ NO ___ 9 Do the fan rotate freely YES ___ NO ___ 10 Is copper tub...

Page 30: ...he responsibility of the owner and or maintenance service contractor to document any service repair or adjustments CAP Warranty Department is available to advise and provide phone help for proper operation and replacement parts The responsibility for proper start up maintenance and servicing of the equipment falls to the owner and qualified licensed technician ACTION DATE ACTION TAKEN NAME TELEPHO...

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CAP AHU, Installation And Maintenance Instructions Manual

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