United CoolAir VariCool EZ-Fit 12, Installation, Operation And Maintenance Manual

Page 1: ...VariCool EZ Fit Series Installation Operation and Maintenance Manual Effective January 2018 Variable Air Volume Water Cooled and Chilled Water ...

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Page 3: ...intenance Procedures 21 Filters 21 Blowers 21 Lubrication 21 Belt Driven DWDI 21 Frequency of Lubrication 21 Belt Tensioning 22 Direct Drive Blowers 22 Drain Pan 23 Evaporator Coil 23 Coil Cleaning 23 Condenser Cleaning 23 Water Side Economizer Coil 23 Water Valves 23 Refrigerant Systems 24 Operations Verification Check List 25 Troubleshooting Guide 26 Limited Warranty 29 Important Notice 29 Exclu...

Page 4: ... in minor or moderate injury if not avoided The information icon indicates a situation that may result in equipment or property damage The information provided alerts the reader to relevant facts and or conditions ELECTRICAL HAZARD WARNING CAUTION INFORMATION This publication includes warnings cautions and information icons that point out safety related issues or conditions as well as other pertin...

Page 5: ...Use caution when moving the unit or modules so that damage does not occur when moving each piece to the final installation location within the structure The units or modules can be moved by the use of a crane fork lift pallet jack or roller bars as appropriate Under no circumstances should the unit or modules be walked on the corners of the skid or unit If a crane cables or slings are used to move...

Page 6: ...Clearances TOP TOP TOP 24 24 36 24 24 24 24 24 36 24 24 24 36 36 TOP Single DWDI Modules Dual Modules Single DDP Modules Notes a Service clearances apply to all air path configurations b Service clearances apply to all size units c Service clearances apply to both DWDI and DDP blower models in dual module configuration ...

Page 7: ... be of sufficient depth in water column to permit the condensate to flow from the drain pan Failure to have a sufficient drain trap will cause the condensate to overflow the drain pan or to cause the unit to shut down on the drain pan overflow safety The A dimension Ref Figure 2 must equal or exceed the negative static pressure developed by the supply air blower The A dimension will be unique for ...

Page 8: ...rking Pressure Fluid 400 psig Return Air Duct Size 51 3 8 H x 40 W 55 H x 50 1 2 W Supply Air Duct Size 16 1 4 H x 18 7 8 W 19 H x 22 3 16 W Compressor Type Hermetic Scroll Qty 2 Refrigerant Type R 410a Lbs Ozs 10 5 13 15 17 Weight b Net Operating Evaporator 375 525 Condensing 800 1075 Blower DWDI 475 575 Blower DDP 500 650 Assembly w DWDI 1650 2175 Assembly w DDP 1675 2250 Dimensions Evap Filter ...

Page 9: ...400 psig Return Air Duct Size 69 H x 60 W 69 H x 64 W Supply Air Duct Size 24 7 8 H x 15 1 2 W 24 7 8 H x 19 W Compressor Type Hermetic Scroll Qty 2 Refrigerant Type R 410a Lbs Ozs 30 40 Weight b Net Operating Evaporator 1000 1170 Condensing 1340 1570 Blower DWDI X X Blower DDP 800 2 1040 2 Assembly w DWDI X X Assembly w DDP 3940 4820 Dimensions Evap Filter 69 W x 27 1 2 D x 71 H 76 W x 29 1 2 D x...

Page 10: ...is also alphabetically labeled so that each section can be mated properly Set the sections so that point A aligns to A B aligns to B C aligns to C etc Mounting Options When installing any floor mounted unit it is sometimes desirable to include some form of vibration isolation Please note that the unit frames have not been designed for corner point only loading with vibration isolation methods Vibr...

Page 11: ...g will not occur It is also important that all the channels are level before placing the unit atop them Please note the locations of the pads Figure 3C Base Option 2 Bottom View Figure 3D Base Option 2 Unit View If height and other reasons prevent adequate space for framing waffle pads alone may be used reference figure 3E It is highly recommended that each pad be of identical height and that the ...

Page 12: ...entified as 2 in Figure 4 evaporator and compressor condensing section Compressor Condenser Section Next locate the compressor condenser section s Again make sure the labels align properly for either the single or dual module applications On the refrigerant resealable fittings apply a few drops of refrigerant oil to the male coupling halves before starting the assembly Ref to Figure 6 3D Intellicl...

Page 13: ...nual VariCool EZ Fit 13 Subject to change without notice 40 20 IM 0118 Figure 5A 20 70 Ton Single LEFT RETURN AIR ELECT VFD REAR RIGHT FRONT MOTOR IN OUT TIGHTENING SCREW DETAIL A DETAIL A TYP 8 PLCS MOUNTING SCREWS 12 35 TON SINGLE FIGURE 5A ...

Page 14: ...4 Subject to change without notice 40 20 IM 0118 Figure 5B 20 70 Ton Dual FRONT R A E R T H G I R MOTOR MOTOR N R U T E R N R U T E R R I A R I A ELECT VFD VFD ELECT IN OUT TIGHTENING SCREW DETAIL A DETAIL A TYP 16 PLCS MOUNTING SCREWS LEFT 24 70 TON DUAL FIGURE 5B ...

Page 15: ... to change without notice 40 20 IM 0118 Figure 5B 20 70 Ton Dual Blower REAR RIGHT FRONT LEFT RETURN AIR RETURN AIR MOTOR MOTOR MOTOR MOTOR MOTOR ELECT VFD VFD ELECT IN OUT MOTOR DETAIL A TYP 16 PLCS TIGHTENING SCREW DETAIL A MOUNTING SCREWS 20 70 TON DUAL BLOWER FIGURE 5C ...

Page 16: ... rotations are required for proper sealing of the fittings Size Wrench Full Turns Required 3 8 1 3 16 6 1 2 1 3 16 6 5 8 1 5 8 7 3 4 3 4 1 5 8 7 3 4 7 8 1 5 8 8 1 1 8 2 8 Table 1 Resealable Fitting Turns INFORMATION If low refrigerant pressure is evident during the start up process check the tightness of all resealable fittings A fitting that is not fully open will restrict refrigerant flow Supply...

Page 17: ...not less than 7 0 or higher than 8 0 for proper heat exchanger life If this is not possible the unit should be verified to have had specialty coatings or heat exchanger coils installed if reasonable life of the heat exchangers is to be expected The following items are to be field supplied and applied A Water shut off valves Gate or Ball Type B Inlet water strainer with isolation shut off valves on...

Page 18: ...Tons Size Single Module 12 1 1 2 15 1 1 2 20 2 25 2 30 2 1 2 35 2 1 2 Dual Modules 24 2 30 2 40 2 1 2 50 2 1 2 60 3 70 3 Table 2 Water Connection Sizes The water piping that is installed internal to the modules in the field will need to be wrapped to minimize any condensate forming on the piping The same gasket material used to seal between the module sections can be used to accomplish this Dual m...

Page 19: ...boxes close and the call for the unit operation has not subsided and over pressurizes the duct work The duct static switch requires field tubing installation The tubing must be mounted in the supply side of the duct work and external to cabinet pressure There is an adjustment on the switch to set the trip point in W C It is inside the switch accessible by removing the 2 front screws Simply adjust ...

Page 20: ...ters if possible For maintenance room plenum applications the return sensor should not be placed anywhere that can be influenced by outside sourced temperatures Common items influencing the return temperature sensor are large transformers computers control panels doorways outside air dampers water heaters sinks and washbasins etc Shipped loose Item Voltage Unbalance Voltage unbalance occurs when t...

Page 21: ... filters can simply be lifted up to clear the lower frame edge and pulled towards you for removal The filters are directionally specific for air flow reinsert the new filter in the correct air flow direction Blowers Check that the blower wheel is tight on the shaft and does not contact the blower housing DWDI type Check for restrictions or foreign material in the air circuit Lubrication Belt Drive...

Page 22: ...d to use is listed in the following equation Deflection Belt Span 64 Belt span is in inches from center pulley to center pulley see Figure 8 Belt tension is adjusted by using the adjusting bolt on the end of the motor mounting frame Check the alignment of the sheaves to make sure that the sheave faces are in the same plane Check this by placing a straight edge across the face of the sheaves Any ga...

Page 23: ...e the coil and associated safety devices or refrigerant components CAUTION Confirm that any coil cleaning agents detergents or solutions are suitable for use on a copper tube aluminum fin coil If the cleaning agent is to acidic or alkaline damage to the coil fins may result Rinse all coils thoroughly after any coil cleaning Use a suitable fin comb after the coil cleaning to straighten any bent fin...

Page 24: ... obstructions If the temperature drop across the filter drier is more than 3 to 5 there is a good likely hood that the filter drier is blocked to some ex tent and should be replaced The sight glass contains a moisture indicator that changes color when moisture is present in the refrigerant system glass If the color of this indicator is green or blue the refrigerant is normal When the indicator is ...

Page 25: ...erformed at the same time with similar operating parameters to obtain the CFM 3 Water balance verification Ensure that the unit has 3 gpm per ton available to it at all times if a pump is of variable speed it must be able to ramp up its speed based on that demand To test the full water demand of the unit you must use the controller on the unit and apply a manual control to the discharge pressure c...

Page 26: ...the condenser 5 Resolve incoming voltage issue 6 Resolve alarm condition Note Compressor internal overload may require an extended period of time 1 hour or more to reset Compressor short cycles 1 Reduced air flow 2 Loss of refrigerant charge 3 Short cycling of conditioned air 4 Drain pan switch open 1 Check filters and coil for any blockages 2 Replace filters if dirty 3 Repair leak evacuate and re...

Page 27: ...mal expansion valve bulb is tight on suction line 5 Confirm thermal expansion valve bulb is located properly on suction line 6 Replace thermal expansion valve 7 Replace filter drier 8 Check filters and coil for any blockages 9 Replace filters if dirty 10 Verify that blower is rotating in the proper direction 11 Confirm proper fluid flow quantity through condenser 12 Confirm acceptable fluid temper...

Page 28: ...er not set properly 2 Control wiring issue 3 Controls in an alarm condition 4 High or low pressure switch open 5 Compressor thermal overload open 1 Turn on and set controller for desired operation 2 Check wiring connections against schematic 3 Check all connections for tightness 4 Check wire continuity 5 Refer to controller troubleshooting 6 Reset high or low pressure switch 7 Compressor internal ...

Page 29: ...side of condenser and evaporator 9 Damages resulting from I freezing of condenser water or condensate II use of corrosive water III fouling or restriction of the air water circuit by foreign material or like causes 10 Damages resulting from operation with inadequate or interrupted supply of air or water 11 Damages resulting from use of components or accessories not approved by United CoolAir 12 Th...

Page 30: ...al or like causes 10 Damages resulting from operation with inadequate or interrupted supply of air or water 11 Damages resulting from use of components or accessories not approved by United CoolAir 12 This warranty does not apply to the installation plumbing and wiring not integral to the product 13 Damages resulting from improper application or sizing This warranty is in lieu of all other warrant...

Page 31: ...olAir 12 This warranty does not apply to the installation plumbing and wiring not integral to the product 13 Damages resulting from improper application or sizing of unit 14 In the event that the refrigerant type is changed as a result of a compressor failure and the same type of compressor is not available any subsequent refrigerant circuit component failures will not be covered under the Limited...

Page 32: ...essories not approved by United CoolAir 12 This warranty does not apply to the installation plumbing and wiring not integral to the product 13 Damages resulting from improper application or sizing 14 Discharge air temperature control if not provided by the factory will void the compressor Limited Warranty 15 In the event that the refrigerant type is changed as a result of a compressor failure and ...

Page 33: ... flooded condenser option the scroll compressors will have crankcase heaters If the outdoor ambient is 70 F or lower let the compressors sit for approximately 24 hours before proceeding 12 Record the voltage at the unit terminals 13 If possible with the thermostat provided switch the evaporator blower to the RUN position Verify that the evaporator blower is activated 14 Verify that the evaporator ...

Page 34: ... pressures on each compressor circuit are within the proper limits i 290 550 Discharge ii 100 140 psig Suction b Compressor Amperage is below the RLA Amps listed on the unit data tag i The maximum compressor operating current amps at start up depends a lot on the system loading The lower the load the less the current The higher the load the higher the current c The blower motor FLA values should n...

Page 35: ...ontact the Distributor Is the Circuit Protection the correct type and does it meet the unit data tag requirements Yes ____________ No ____________ If not correct describe what action s have been taken to correct Unit controller wiring verified Yes ____________ No ____________ C Terminal hooked up if necessary Yes ____________ No ____________ Unit leak checked OK Yes ____________ No ____________ If...

Page 36: ... Temperature Liquid Line Temperature F_________ F_________ F_________ F_________ F_________ F_________ F_________ F_________ Sub cooling _________ _________ _________ _________ Electrical Evap Motor Amps L1_____________ L2____________ L3_____________ Compressor 1 Amps L1_____________ L2____________ L3_____________ Compressor 2 Amps L1_____________ L2____________ L3_____________ Cond Motor Amps L1_...

Page 37: ...t for approximately 24 hours before proceeding 12 Record the voltage at the unit terminals 13 If possible with the thermostat provided switch the evaporator blower to the RUN or ON position Verify that the evaporator blower is activated 14 Verify that the evaporator blower is rotating in the correct direction three phase units only Note If the evaporator blower motor runs backwards shut off all po...

Page 38: ...ponding to the liquid line pressure 32 Calculate and record the liquid sub cooling for each circuit by taking the difference between the liquid line temperature and the saturation temperature corresponding to the liquid line pressure 33 Record the Amps for the evaporator blower motor and each compressor If the system is single phase use L1 and L2 only a Make sure the pressures on each compressor c...

Page 39: ...ibutor Is the Circuit Protection the correct type and does it meet the unit data tag requirements Yes ____________ No ____________ If not correct describe what action s have been taken to correct Unit controller wiring verified Yes ____________ No ____________ C Terminal hooked up if necessary Yes ____________ No ____________ Unit leak checked OK Yes ____________ No ____________ If leak was locate...

Page 40: ...i________ F_________ psi________ F_________ psi________ F_________ Saturation Temperature F_________ F_________ F_________ F_________ Suction Superheat _________ _________ _________ _________ Liquid Line Pressure psi________ psi________ psi________ psi________ Saturation Temperature Liquid Line Temperature F_________ F_________ F_________ F_________ F_________ F_________ F_________ F_________ Sub ...

Page 41: ...angement Dual Module Arrangement Single Dual Dual Triple Circuit Four Circuit Circuit AF Two Fixed BF Three Fixed DF Four Fixed AD 2 Digital BD 3 Digital DD 1 Digital 3 Fixed ADF 1 Digital 1 fixed BDF 1 Digital 2 fixed DDF 2 Digital 2 fixed AVF 1 Variable Speed BVF 1 Variable Speed DVF 1 Variable Speed 1 Fixed 2 Fixed 3 Fixed AV 1 Variable Speed BV 2 Variable Speed DV 2 Variable 2 Fixed No Compres...

Page 42: ...Installation Operation and Maintenance Manual VariCool EZ Fit 42 Subject to change without notice 40 20 IM 0118 NOTES ...

Page 43: ...Installation Operation and Maintenance Manual VariCool EZ Fit 43 Subject to change without notice 40 20 IM 0118 NOTES ...

Page 44: ... on the compressor labor not included Maintenance items such as filters and belts are excluded under this limited warranty FACTORY TESTED All units are functionally run tested before shipment to ensure a trouble free start up and unit commissioning Industry proven components are used throughout to enhance system reliability and peace of mind VertiCool Classic Vertical 3 30 Ton VertiCool Aurora Ver...