United CoolAir 4CA1901 Installation Manual Download

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Installation Manual

“C” SERIES HORIZONTAL

AIR CONDITIONING UNITS

1 Ton – 15 Ton

Air-Cooled • Water-Cooled • Heat Pump

for

590A

Summary of Contents for 4CA1901

Page 1: ...Installation Manual C SERIES HORIZONTAL AIR CONDITIONING UNITS 1 Ton 15 Ton Air Cooled Water Cooled Heat Pump for 590A ...

Page 2: ...2 FORM CIM 0203 ...

Page 3: ...ed Adjustment 18 Blower Motor Lubrication 18 Belts 19 Refrigerant Systems 19 Evaporator and Air Cooled Condenser Coils 19 Minimum Service Access 19 Application Data 19 Positive Temperature Coefficient Resistor 20 SECTION 6 PHYSICAL DATA Figure 21 Physical Data Table 21 SECTION 7 SEQUENCE OF OPERATION Cooling Sequence of Operation 23 Heating Sequence of Operation other than heat pump 23 Heat Pump H...

Page 4: ...Dual Circuit 10 Ton Dual Circuit 12 and 15 Ton 80 7 8 70 3 8 29 45 1 8 35 1 2 30 24 2 1 2 2 3 4 14 1 2 20 25 1 3 8 Triple Circuit NOMINAL P Q R S T U V W X Y Z AA BB TONS 1 and 1 1 2 Ton 1 3 16 12 3 7 8 2 3 8 37 5 16 25 1 4 4 7 8 4 5 8 15 7 32 14 11 16 4 Single Circuit 2 through 5 Ton 3 4 5 1 4 24 16 2 7 8 2 3 8 48 5 8 21 9 16 4 1 8 7 5 16 22 1 16 20 11 16 4 Single Circuit 4 through 8 Ton 3 11 16 ...

Page 5: ... 970 lbs 925 lbs 585 lbs 540 lbs DUAL COMP 6 TON 970 lbs 925 lbs 585 lbs 540 lbs DUAL COMP 8 TON 995 lbs 945 lbs 600 lbs 550 lbs DUAL COMP 10 TON 1340 lbs 1205 lbs 800 lbs 665 lbs DUAL COMP 12 TON 1520 lbs 1375 lbs 915 lbs 770 lbs TRIPLE COMP 15 TON 1580 lbs 1450 lbs 950 lbs 820 lbs TRIPLE COMP NOTE CONDENSATE DRAIN MUST BE PIPED IN BOTH EVAPORATOR AND CONDENSING SECTIONS NOMINAL A B C D WATER CON...

Page 6: ...iringConnection Power Wiring Connection for package units and for conden sing sections in split systems 590A 7 1 8 B A D C 6 Figure 6 Unit toward condensing section and left side 591A 17 2 19 3 16 6 LEGEND OF ITEMS Tie Rail Evaporator Access Panel Unit Top Tie Piece Evaporator Condensate Drain Condenser Drain Grommet LowAmbient Tube Condenser Access Panel Filter Access Panel Condensate Pump Connec...

Page 7: ...oved LEGEND OF ITEMS Tie Rail Unit Top Tie Piece Wires to Disconnect Split unit Specification Plates Thermostat Wiring Connection for both package and split units Power Wiring for unit evaporator Low Voltage Wiring Connection Power Wiring Connection 594A 1 9 A C B D EVAPORATOR CONDENSER 6 9 23 ...

Page 8: ...g liquid line 13 Evaporator Drain Connection 14 Filter drier 15 Thermal Expansion Valve 16 Evaporator Coil 17 Air Filter 18 Evaporator Blower 19 Evaporator Motor 20 Electrical Control Box Evaporator 21 Air Switch used only when Electric Heat is incorporated 22 Liquid Service Port Figure 9 Split Unit Evaporator Section 19 11 12 13 14 15 16 17 18 20 21 597A Figure 8 Split Unit Condensing Section 596...

Page 9: ...eremoval trapping and disposal DischargeAir from condenser coil should be deflected away from supply air to condenser to prevent recirculation See also Condens ing Section Modification for Outside Instal lation on page 31 CAUTION Unit should NOT be located in space subjected to freezing temperatures MOUNTING AND SETTING IN PLACE Units can be shipped as an integral package with a tie rail Items and...

Page 10: ...nect to low voltage terminal block supplied See Thermostat under Options page 25 Properly locate thermostat to avoid vibration drafts sunexposure orinternalheatsources Use an inside wall COMPRESSOR MOUNTING WARNING Compressors on some units are spring mountedbutaretighteneddownforshipping Before initial start up compressor nuts must bebacked offtothepointwheretheyareflush with the top of the studs...

Page 11: ...ss Kit 1 For single circuit use one kit for dual circuits use two kits for triple circuits use 3 kits 2 Interconnect kits for 1 and 1 1 2 Ton units are the same as kits for other tonnage except for the self sealing couplings on the suction line which are part number 6CA1005 for the female half and 6CA1006 for the male half ITEM QUANTITY DESCRIPTION PART 4 2 Schrader Access Valves 6CA1101 1 Self Se...

Page 12: ... to the outside of the back panel of the evaporator sec tion at the location vacated by the original cou plings using the flanges Item and screws Item provided in the kits See Figures 13 and 14 The panel has holes to accept the screws Item tobeutilized Mountmalecou pling halves same as Item by sliding the flanges Item frominterconnectkit overend of couplings before brazing tubing and attach with s...

Page 13: ...elf sealing coupling halves evacuate each line to 500 microns Check to make sure that each line holds a vacuum after removal of the vacuum pump indicating no leaks Add the appropri ate charge of R 22 Refrigerant using the Schrader valves Refasten male halves to outer back panel of evaporator section with flanges and screws if they were removed for brazing to tubing Wipe off coupling seals and thre...

Page 14: ... minimum circuit ampacity and maximum fuse size per the National Electric Code DUCT CONNECTION It is recommended to use a flex collar or other means to isolate any unit vibration from being transmitted to the duct or structure Ductwork and plenums shall be insulated in accor dance with applicable ASHRAE standards or local codes PRESSURE SWITCHES High Pressure This switch shuts the unit down in the...

Page 15: ...ystem requires 3 gallons of water per ton per minute Braze in your pipe water lines to the water valve s Forfuturereferencewhencleaningisneeded record details on temperatures entering and leaving the heat exchanger and the pressure drop as a new installation See Cleaning The Water Cooled Con denser on page 16 Water Connection Install and connect a fresh water strainer not sup plied to the water in...

Page 16: ... 10 or greater change has occurred it would be beneficial to clean the heat exchanger A 5 solution of Phosporic Acid or Oxalic Acid 6 one for the condensing section Item Figure 6 page 6 All units require evaporator section drains to be installed Heat pumps and water cooled con densing units also always require the installation of acondensingsectiondrain Unitswithaircooledcon densers need a condens...

Page 17: ...ative cleaner that all com ponents will withstand or create another method of circulating the cleaner that would isolate the com ponent in question from the cleaner While cleaning the heat exchanger it may also be a good idea to check and clean the strainer as well NOTE Do not chemically clean a refriger ant circuit 1 Record performance values Ref following charts Turn off the fluid source 2 Cool ...

Page 18: ... 6000 15 Ton 6000 7500 Figure 20 Fan Capacities On units with three phase fan motors check forproperblowerrotation at start up If they run backwards interchange two of the in coming power leads BLOWER MOTORS All blower motors are equipped with thermal over load protectors CAUTION Open disconnects to unit as mo tor will start when automatic thermal over load resets BLOWER SPEED ADJUSTMENT Blower sp...

Page 19: ...eam of the sightglass However bubbles will appear every now and then in units with the hot gas bypass option Bubbles will also appear upon compressor start up but normally clear to pure liquid after a few minutes of operation The sightglass contains a moisture indicator which changes color when moisture is present in the sys tem This indicator is the circulator dot in the cen ter of the sight glas...

Page 20: ... device will start at approximately 100 ohms and then quickly increase to approximately 30 000 ohms This provides about 2 to 2 1 2 times the normal starting torque for the compressor After the initial start period the PTCR device will heat up as the resistance increases and block ad ditional power flow through the start windings When the compressor shuts off a 3 to 5 minute cool down period is nee...

Page 21: ... 1 1 to 1 Cond Blower Size 7 x 7 7 x 7 12 x 9 12 x 9 12 x 9 12 x 9 HP 1 2 1 2 3 4 1 1 1 2 2 Qty 1 1 1 1 1 1 Condenser Coil Rows Deep 3 3 3 3 4 4 Face Area 2 6 2 6 4 4 4 4 4 4 4 4 Water Cooled Cond Pressure Drop b 3 7 9 42 7 6 4 8 76 10 2 GPM 3 4 5 6 9 12 15 Int Volume 0 1 0 1 0 2 0 3 0 4 0 7 Water Gallons Compressor Qty 1 1 1 1 1 1 Charge R 22 Water Cooled 2 0 2 0 2 8 3 0 4 12 5 0 Lbs Ozs c Air Co...

Page 22: ...9 15 x 15 15 x 15 15 x 15 HP 1 1 2 2 2 3 5 5 7 5 Qty 1 1 1 1 1 1 1 Condenser Coil Rows Deep 6 6 6 6 8 8 8 Face Area 6 4 6 4 6 4 6 4 7 3 7 3 7 3 Water Cooled Cond Pressure Drop b 7 8 1 6 4 8 8 10 2 8 8 10 2 GPM 12 15 18 24 30 36 45 Int Volume 2 ea 2 ea 3 ea 4 ea 7 ea 4 ea 7 ea Water Gallons Compressor Qty 2 2 2 2 2 2 Charge R 22 Water Cooled 2 14 ea 3 4 ea 3 14 ea 4 0 ea 5 0 ea 4 0 ea 5 0 ea Lbs Oz...

Page 23: ... desired space tem perature and the Fan switch to AUTO or ON The unit will cycle as required to maintain conditions 4 Chill water sequence is the same as above ex cept compressor activation is replaced by the chill water valve function 5 Heat pump cooling sequence is the same as above except the reversing valve will also be activated when the compressor cycle is started HEATING SEQUENCE OF OPERATI...

Page 24: ...instructions for that device may be re quired a Lower thermostat setpoint to the lowest level b Set System switch to OFF position c Set Fan switch to AUTO position d Moving the Fan switch to the ON posi tion should cause the evaporator blower mo tor to run Moving the Fan switch back to AUTO should stop the blower e Move the System switch to the HEAT po sition Slowly raise the thermostat setting to...

Page 25: ...T Standard units no heating with one compressor re quire single stage thermostats cool only Units with two or three compressors require dual stage thermo stats cool only Whenaprogrammablethermostatisused asixthcon tact must be added to the terminal board in the evapo rator section Three connections must be made from this sixth contact to the programmable thermo stat to a ground and to the 24 volt ...

Page 26: ...e system to stabilize after each turn 5 Vary the evaporator load to test at various con ditions that the suction pressure does not fall below the set point 58 psig for R 22 6 Replace the seal cap on the top of the hot gas bypass valve NOTE a On split system applications the hot gas bypass line to the evaporator should be in sulated to prevent condensation b Use a wet rag around the hot gas bypass ...

Page 27: ...t The other end of the 1 4 tube with flare nut is run through a grommet in the condenser panel Item Figure 6 page 6 to the liquid access fitting marked Low Ambient Damper located in the condensing sec tion NOTE On 4 to 15 Ton units with dual or triple refrigerant circuits it is EX TREMELYIMPORTANT that the 1 4 tube from the damper pressure operator be con nected to the liquid line access fitting o...

Page 28: ...build up to the cut in point of the low pressure control The result may be a failure of the compres sor to start or to short cycle To eliminate this po tential problem a time delay is added to bypass the low pressure switch during start up BUCK BOOST TRANSFORMER Units being applied on a 277 1 60 power supply require the use of a buck boost transformer The transformer will reduce the voltage from 2...

Page 29: ...he system electrical control circuit dia gram for proper wiring to integrate the enthalpy sensor and damper controller into the remainder of the system control circuitry ECONOMIZER OPERATION WATERSIDE The waterside economizer is also referred to as a free cooling coil The free cooling coil is installed after the DX cool ing coil in the cabinet is to be mounted in the outlet line of the coil COMPRE...

Page 30: ...f water and snow being pulled in The screens keep debris wild life and hands out of unit See Figure 27 for vari ous sizes VERTICAL STACKING UNIT The vertical stacking option is designed for instal lations where floor space is minimal and a ceiling space is not available The evaporator section is placed above the condensing section for location in small spaces Evaporator discharge air is avail able...

Page 31: ... 0006VI Figure 30 Vertical Stacking Unit Rear View 0005VI 0011CA Figure 28 Condensing Section Modification Kit For Outside Installation Optional UNIT SIZE A B 1 1 1 2 Ton 15 36 1 2 2 through 5 Ton 19 48 4 through 8 Ton 24 56 10 through 15 Ton 26 71 1 4 Figure 27 ...

Page 32: ...3 4 31 3 8 16 18 1 1 4 3 4 24 16 2 7 8 2 3 8 7 5 16 22 1 16 4 1 8 16 10 3 8 16 1 3 3 8 16 4 3 4 4 thru 8 56 55 1 4 27 40 1 4 31 3 8 18 23 1 3 8 3 11 16 32 16 2 7 8 2 3 8 7 5 16 22 1 16 3 9 16 18 15 3 16 18 1 8 7 8 20 4 13 16 10 thru 15 60 70 3 8 29 45 1 8 35 1 2 20 25 1 3 8 2 3 16 38 18 1 11 16 11 1 4 7 5 16 25 7 8 5 3 8 30 14 1 2 20 1 9 5 8 24 2 1 2 Figure 31 Outline Dimensions For Air Cooled Ver...

Page 33: ...8 3 11 16 32 16 2 7 8 2 3 8 7 5 16 22 1 16 20 11 16 3 9 16 1 8 7 8 60 10 through 15 60 70 3 8 29 45 1 8 35 1 2 20 25 1 3 8 2 1 2 38 18 1 11 16 11 1 4 7 5 16 25 7 8 21 1 8 5 1 2 1 9 5 8 75 Figure 32 Outline Dimensions For Water Cooled Vertical Style Units WATER CONNECTIONS UNIT AA BB CC PIPE SIZE 1 and 1 1 2 Ton 8 10 6 In Out 7 8 O D Left Side 2 through 4 Ton In Out 7 8 O D Left Side 5 Ton 10 12 6 ...

Page 34: ... leak and recharge refrigerant system refrigerant charge 3 Compressor fails to Head pressure too high Check condenser for obstructions and remove start high pressure switch Check for the required water flow through the open water regulating valve and the condenser coil Manually reset thermostat With Marvel turn off alarm and reset PTCR will keep Wait for PTCR to cool off Compressor should compress...

Page 35: ... compressor valve compressor 6 Noisy compressor knocking Worn or scarred Replace compressor compressor bearings Liquid slugging System overcharged Reclaim excess refrigerant from the high side of the system Excessive head pressure Reduce head pressure see item 8 below Flash gas in liquid line Check for leaks Repair and bubbles in sight glass recharge the system Expansion valve stuck Replace Valve ...

Page 36: ... line Repair leak and recharge bubbles in sight glass due to a leak Obstructed expansion Repair or replace valve valve Suction pressure too 10 low Loss of fluid within Replace power head and valve expansion valve bulb Clogged filter drier Replace with new filter drier Ice or dirt on evaporator Defrost and clean evaporator coil coil and replace filter Thermostat set too low Adjust thermostat to the...

Page 37: ...mp to move freely does not run Dirt or algae not Clean pump and float not allowing float to activate pump Tubing blocked or kinked Inspect clean or straighten as necessary Check valve blocked Clean check valve 15 Condensate Pump runs with no discharge Inpeller blocked Remove debris from pump impeller Tubing elevation or run Verify tubing run is within pump exceeds head capability head limitations ...

Page 38: ...tions NOMINAL B C D F G M N P PIPING OUTLET TONS LOCATIONS 1 and 1 1 2 Ton 35 13 16 16 29 3 8 12 12 12 3 4 5 Row I Single Circuit 2 thru 5 Ton 47 1 4 22 34 3 4 16 16 16 4 1 2 5 0 Row I Single Circuit 4 thru 8 Ton 55 1 4 27 40 1 4 18 20 18 4 1 2 5 0 Rows I II Dual Circuit 10 Ton 70 3 8 29 45 1 8 30 24 20 4 1 2 5 0 Rows I and III Dual Circuit 12 thru 15 Ton 70 3 8 29 45 1 8 30 24 20 4 1 2 5 0 Rows I...

Page 39: ...Heating _________________________________________________ RH _________________________________________________ Design CFM ______________ ______________ ESP Voltage ____________________________ EWT _______________ GPM __________ EAT _______________________________ OD Design __________________________ Controls Calibrated Y N Air Balance Completed Y N Service Agency __________________________________...

Page 40: ...illed Water Unit 1 thru 15 Tons E When E appears as a prefix to any of the above it is the Evaporator Section only of the unit 1 thru 15 Tons B When B appears as a prefix to any of the above it is the Condensing Section only of the unit 1 thru 15 Tons b 2 3 4 5 6 8 10 12 15 Nominal Cooling Capacity in Tons 12 or 18 for SP units 1 1 5 Tons c G Common to all d 1 3 4 or 7 Indicates Voltage 1 208 230V...

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