MODEL ESP-D SYSTEM INSTALLATION, OPERATION & …€¦ · 13 17 17 17 17 18 18 19 IN UNITED STATES:...

SECTION 1: INTRODUCTIONSpace-Pak System Design.......................................Code Compliance.....................................................Air Distribution Requirements...................................Air Distribution Components.....................................Warranty Information................................................Shipment of Unit.......................................................

SECTION 2: SYSTEM INSTALLATIONStep 1: Locating The Unit.........................................Step 2: Cutting Return Air Opening..........................Step 3: Attaching Supply Air Plenum Ring...............Step 4: Setting The Unit............................................Step 5: Installing The Condensate Trap & Line.........

222355

689

1112

Step 6: Wiring The Unit.............................................Step 7: Installing Air Distribution Components..........

SECTION 3: START UP & OPERATIONSequence Of Operation.............................................Prior To Start-Up........................................................System Start-Up & Adjustements..............................Charging Cooling Only Systems ..............................

SECTION 4: MAINTENANCEBefore Each Cooling Season....................................If System Fails To Operate........................................Parts List...................................................................

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17171717

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IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 (413) 564-5530/FAX (413) 564-5815IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONTARIO, L4W 1R3 (905) 625-2991/FAX (905) 625-6610

Central Air Conditioning Series2 to 5 Tons

Fan Coil Unit/Air SupplyComponents

MODELESP-D SYSTEMINSTALLATION,

OPERATION& MAINTENANCE

MANUAL

ESPD2-30142-9469

The following terms are used throughout this manual to bring attention to the presence of potentialhazards or to important information concerning theproduct:

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or property damage.

NOTICE: Used to notify of special instructions oninstallation, operation or maintenance which areimportant to equipment but not related to personalinjury hazards.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result indeath, serious injury or substantial propertydamage.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result indeath, serious injury or substantial property damage.

2

SPACE-PAK SYSTEM DESIGNSpace-Pak is a hi-velocity central air conditioning systemwhich utilizes a conventional outdoor condensing unitmatched with the indoor Model ESP-D fan coil unit to provided conditioned air through the specially-designed,pre-fabricated, pre-insulated flexible duct system. Thesystem and its basic components operate the same as inany conventional air-to-air cooling system.

The Space-Pak system is covered by the following U.S. Patents: 3,507,354; 3,575,234; 3,596,936;3,605,797; 3,685,329; 4,045,977; 4,698,982; 926,673and Canadian Patents: 891,292; 923,935; 923,936.

CODE COMPLIANCEFan coil unit installation must conform to the require-ments of the local authority having jurisdiction or, in theabsence of such requirements, to the National Board ofFire Underwriters regulations. Fan coil unit meets ETLlisting requirements.

All electrical wiring must be in accordance with theNational Electrical Code ANSI/NFPA No. 70-latest edition and any additional state or local code require-ments. If an external electrical source is utilized, the fancoil unit, when installed, must be electrically grounded.

AIR DISTRIBUTION SYSTEM COMPONENTREQUIREMENTSAir distribution components installation must conform tothe requirements of local authority having jurisdiction or,in the absence of such requirements, to the NationalBoard of Fire Underwriters Code 90A or 90B.

Do not begin the installation of the system without asystem layout and material take-off. If a layout plan is notalready available and room terminator requirementsdetermined, then refer to the Space-Pak ApplicationManual, SP9, to complete this information. A descriptionof air distribution system components is shown in Figure 1.1.

Section 1: INTRODUCTION

RETURN AIR DUCT

CLAMP BAND

RETURN AIR BOX

PLENUM DUCT

FAN COIL UNIT

PLENUM CAP

PLENUM TEE

PLENUM TAKEOFF

KWIK CONNECTS

SOUND ATTENUATING TUBING

TERMINATOR PLATES

ORIFICE

RIGID 90° ELBOW

3

INSTALLATION KIT COMPONENTS (SPC-50-5A)

Terminator plates (5)with clips and screws

S.A. tubing w/ kwik-connects installed (5)

Kwik-connects (10).Plenum Take-offs (5).

clips and gaskets.

2 ea. 15%, 35% and50% balancing orifices

RETURN AIR BOX (SPC-1D, 2D, & 3D): Each includesfilter grill with metal frame, permanent 14" x 25" x 1"(1D, 2D), 14" x 36" x 1" (3D) filter, and 2 clamp bands.SPC-1D is for ESP-2430D. SPC-2D is for ESP-3642Dand SPC-3D is for ESP-4860D.

RETURN AIR DUCT (SPC-4,5, & 6): Flexible, 6 feetlong with round shape. SPC-4 (15" dia.) for ESP-2430D.SPC-5 (19" dia.) for ESP-3642D and SPC-6 (24" dia.) isfor ESP-4860D.

PLENUM DUCT (SPC-13-8): Rigid, 9" I.D., 11" O.D.fiberglass with aluminum vapor barrier. Each section is 6 feet long.

PLENUM TEE (SPC-14-4A): Same construction asduct.

PLENUM ELBOW (SPC-19-4): Same construction asduct. 14" Radius. Rigid 90°.

PLENUM END CAP (SPC-16-10): Insulated metal cap.

SUPPLY TUBING (SPC-25-100): Flexible, insulated, 2" I.D. and 3 1⁄4" O.D. Each section is 100 feet long.

INSTALLATION KIT (SPC-50-2A & 5A): Each containsappropriate amount of sound attenuating (S.A.) tubingsections, kwik-connects, plenum take-offs, terminatorplates and balancing orifices to complete 2 (SPC-50-2A)or 5 (SPC-50-5A) room outlets.

ADDITIONAL COMPONENTS (not shown)

WINTER SUPPLY SHUT OFF (SPC-42-10): To keepmoisture from collecting in ductwork during wintermonths.

PLENUM HOLE CUTTER (SPC-71-10): To cut 2" holein plenum for plenum take-off installation.

PLIERS (SPC-72): To assure full setting of all clips (fasteners) in plenum take-off.

FIGURE 1.1: AIR DISTRIBUTION SYSTEM COMPONENTS

4

Plenum DuctThe plenum duct can be run in practically any locationaccessible for the attachment of the supply tubing (seesuggested layouts in Figure 1.2). The plenum is normallylocated in the attic or basement, and it is usually moreeconomical to run the plenum where it will appreciablyshorten the lengths of two or more supply runs.

In some two-story split level homes, it may be advanta-geous to go from one level to another with the plenumduct. Whenever necessary, either between floors or alongthe ceiling, the small size of the plenum makes it easy to box in.

PLENUMFOR

ESP- 4860ONLY

PLENUMFAN COIL

UNIT

PLENUMFAN COILUNIT

PLENUMFAN COILUNIT

PLENUMFAN COIL

UNIT

FIGURE 1.2: PLENUM/TUBING LAYOUT EXAMPLES (FOR GUIDANCE ONLY)

The blower coil unit is designed to operate with a totalexternal static pressure of 1.5 inches of water column(minimum 1.0 - maximum 1.5). Excessive static pressureincreases the air flow in individual runs and may causesome or all terminators to be noisy.

For systems with a tee installed as on Unit No. 1 (Figure1.3), the best results are obtained if not more than60% of the total number of system outlets are attached to any one branch of the tee. For systems with a teeinstalled as on Unit No. 2 (Figure1.3), not more than 30% of the total number of system outlets should beattached to the perpendicular branch of the tee.

The larger system capacities (ESP-4860D) are effectedmore by higher system static pressure than the smallersystems. The four and five ton system should beconsidered and handled as two separate smaller units.Installation of the plenum tee closer than the minimumindicated in Fig. 1.3 will reduce performance of thesystem. No supply runs should be installed between unitoutlet and this tee. Static readings on system should betaken before tee.

Supply TubingIn the case of two-story or split-level applications, supplytubing may run from one story to another. It is smallenough to go in stud spaces, but this is often difficult inolder homes because of hidden obstructions in studspaces. It is more common to run the supply tubing fromthe attic down through second story closets to the firststory terminators.

Supply tubing runs in the corners of the second storyrooms can be boxed in and are hardly noticeable sinceoverall diameter is only 31⁄4".

Room TerminatorsTerminators should be located only in the ceiling or floorfor vertical discharge. Horizontal discharge is acceptable,but is sometimes more difficult to install. Two excellentspots for horizontal discharge are in the soffit area abovekitchen cabinets (see Figure 1.4) and in the top portionof closets (see Figure 1.5).

Terminators should always be out of normal trafficpatterns to prevent discharge air from blowing directly onoccupants. And they should not be located directly aboveshelves or large pieces of furniture. Outside wall orcorner locations are recommended if the room has morethan one outside wall. Locating terminators away frominterior doors prevents short cycling of air to the return airbox.

WARRANTY INFORMATIONRefer to the Limited Warranty published on the backpage of this manual.

SHIPMENT OF UNITEach fan coil unit is shipped in a single carton. Packedwith the unit, there is a supply air plenum flange withgasket, vibration isolation pads, a condensate trapassembly and a length of 6" wide foil faced fiberglassinsulation.

UNIT NO. 1

UNIT NO. 2

FAN COIL UNIT

FAN COIL UNIT

NO MORE THAN60% OF CAPACITY

ON ONE SIDE

30% MAX. OF CAPACITY

MINIMUM 18"

MINIMUM 18"

FIGURE 1.3: ESP-4860D INSTALLATION

AROOMTERMINATOR

FIGURE 1.4: TERMINATOR IN SOFFIT AREA

A AAAAAA

SUPPLYTUBING

ROOMTERMINATOR

FIGURE 1.5: TERMINATOR IN CLOSET TOP AREA

5

6

SECTION 2: SYSTEM INSTALLATION NOTICE: Before proceeding with the installation, werecommend reading through this section of themanual for an overall understanding of the airconditioning fan coil unit and air distribution systemcomponent installation procedures.

STEP 1: LOCATING THE UNITThe fan coil unit may be installed in an unconditionedspace (as long as it is protected from the weather) suchas an attic, garage or crawlspace...or a conditionedspace such as a basement, closet or utility room (seedimensions in Figure 2.2 and 2.3).

The fan coil unit is shipped in a horizontal air flowarrangement, but can be easily field-converted to avertical air flow arrangement (see Figures 2.8 and 2.9).

When selecting a location, consider the locations asshown in Figures 2.4, 2.5 and 2.6 of the return air box;routing of the plenum duct, supply tubing, refrigerantlines, condensate drain line; and all recommendedclearances (see Figures 2.2 and 2.3).

When installing unit in an attic (above a room ceiling),recommend installing a secondary drain pan or optionalfloat switch. Follow local code requirements.

11-5/16"

6"3-1/2"

1-5/8"

7"

1" B

C

28-1/2"30"

1-5/8"

5-1/2"

A

2-1/2"

D

14"

MODEL A B C

ESP-2430D 24-1/8" 12" 16-7/8"

ESP-3642D 33-1/8" 16-1/2" 24-1/4"ESP-4860D 43-1/8" 21-1/2" 34-1/8"

D

15-3/8"

16-1/2"

21-1/2"

3/8" SWEAT (LIQUID)

7/8" SWEAT (SUCTION)10-7/8" I.D.SUPPLY

3/4" N.P.T.DRAIN CONN.

8" MIN. CLEARANCE 12" MIN. CLEARANCE 38" MIN. CLEARANCE

ELECTRICALCONTROL BOX

RETURNPLENUM

FIGURE 2.2: HORIZONTAL AIR FLOW UNIT DIMENSIONS AND CLEARANCES

Model

Systemcapacity

(Nom. Tons)Suction

LineLiquidLine

Cond.Drain(NPT)

ReturnInlet(Dia.)

Connections

SupplyOutlet(I.D.)

RecommendedCondensing Unit

Capacity(MBH)

MinSEER

ESP-2430D

ESP-3642DESP-4860D

2 - 2-1/2

3 - 3-1/24 & 5

ElectricalCharacteristics

1-60-208/230

1-60-208/2301-60-208/230

7/8"

7/8"7/8"

3/8"

3/8"3/8"

3/4"

3/4"3/4"

15"

19"24"

9"

9"9"

24 to 30

36 to 4248 to 60

12+

12+12+

Model

Systemcapacity

(Nom. Tons)

Std.CFM @

1.5" W.C.Motor

HPF.L.

Amps

No. ofRowsDeep

Blower

Refrig.Charge(R-22)

FlowControlType

Ship.Wt.(lbs)

ESP-2430DESP-3642D

ESP-4860D

2 - 2-1/2 3 - 3-1/2

4 & 5

550 1/31/2

3/4

PSCPSC

PSC

1.82.8

3.6

66

6

0 Exp. ValveExp. Valve

Exp. Valve

117139

166

850

1150

MotorType

0

0

Coil

Wheel Dia.and

Width

9" x 5"

9" x 6-3/8"

9" x 5"

FIGURE 2.1: MODEL ESP-D SPECIFICATIONS

7

MODEL A B C

ESP-2430D 24-1/8" 12" 16-7/8"

ESP-3642D 33-1/8" 16-1/2" 24-1/4"ESP-4860D 43-1/8" 21-1/2" 34-1/8"

D

15-3/8"

16-1/2"

21-1/2"

10-7/8" I.D.SUPPLY

6"3-1/2"

1-5/8"

7"

1" B

11-5/16"

C28-1/2"

30" A

D

14"

3/8" SWEAT (LIQUID)

7/8" SWEAT (SUCTION)

3/4" N.P.T. DRAIN CONN.

8" MIN. CLEARANCE 12" MIN. CLEARANCE

38" MIN. CLEARANCE

ELECTRICALCONTROL BOX

RETURNPLENUM

1-5/8"

5-1/2"

FIGURE 2.3: VERTICAL AIR FLOW UNIT DIMENSIONS AND CLEARANCES

CLAMP BAND

CLAMP BAND

RETURN AIR BOXWITH GRILL & FILTER

SPACE-PAK FANCOIL UNIT

FLEXIBLE RETURNDUCT (90° BEND)

48"

PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4)

SUPPLY AIR OUTLET(ALTERNATE LOCATION)

SUPPLY AIR OUTLET

FIGURE 2.4: TYPICAL UNIT INSTALLATION

14 Ft. MAXIMUM FLEXIBLE RETURN DUCT

FAN COIL UNIT

AAAAAAAAAA

AAAAAA SUPPORT

RETURN AIR BOX

90°

90°

2 Ft. MAX.


AAAAAAAAAAAAAAAASUPPORT

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

FIGURE 2.5: HORIZONTAL AIR FLOW UNIT INSTALLATION

8

STEP 2: CUTTING RETURN AIR OPENINGFor all wall return applications, cut the return air openingto accomodate the return air box according to the samedimensions. Remember, location of opening must allowfor a 90° bend in the return air duct.

Check the opening for proper fit of the return air box. Donot install the return air box until the installation of theentire Space-Pak system is completed, if you want to fitmaterials up through this hole.

FIGURE 2.7: RETURN AIR BOX FRAME DIMENSIONS

AA

14 Ft. MAXIMUM FLEXIBLE RETURN DUCT

AAAAAAA

FAN COIL UNIT

AAAAAAAAAAAAA

AAAAAA SUPPORT

SUPPORT

RETURN AIR BOX

90°

90°

2 Ft. MAX.


AAAAAA

SUPPLYAIR

AAAAAAAAAAA

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

FIGURE 2.6: VERTICAL AIR FLOW UNIT INSTALLATION

Select exact location for return air box. Avoid installingbox in dining room, living room, kitchen, etc., unlessreturn air duct can be installed with 180° bend(accomplished by splicing two return air ducts together.)

For attic installations to raise fan coil unit up throughopening, cut return air opening 141/2" wide by 27" long forthe ESP-2430D and the ESP-3642D and 141/2" wide by37” long for the ESP-4860D. These openings willaccomodate the return air box with sufficient frame lip tocover the opening (see Figure 2.7).

If joists are on 16" centers, the 141/2" width of the returnair box should fit between successive joists. Where joistsrun in the opposite direction, or to properly center thereturn, it may be necessary to cut joists and installheaders.

HINGEDPANEL

LOUVERS

1/2"

A

B

4"

16-1/2" 14-5/16"

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

MODEL A B

SPC-1DSPC-2D

25"36-3/8"

28"38-9/16"

SPC-3D 36-3/8" 38-9/16"

9

STEP 3: ATTACHING SUPPLY AIR PLENUM RING

NOTE: If the unit is to be located in the attic andinstalled through the ceiling joists, attach the supplyplenum flange in the attic.

A. HORIZONTAL DISCHARGE:Refer to Figure 2.8.

B. VERTICAL DISCHARGE:Refer to Figure 2.9A & 2.9BTools required: 5/16" box wrench, 5/16" nut driver, drill and1/4" drill bit.

Refer to Figure 2.9A for Steps 2 to 5a.

1. Place unit horizontally on a flat surface.

2. Remove side access panels, the cover plate from thetop panel and top of unit.

3. Remove the two screws securing the front panelflange to the blower housing.

4. Remove the two screws attaching the blower housingto the motor support channel flange.

5a. Remove the six (6) screws attaching the motormounting base to the motor support channel.

Refer to Figure 2.9B for Steps 5b to 14.

5b. Shift the motor mounting base (and blower housing)back towards the coil to the second set of mounting lugson the motor support channel. When in position, reattachthe motor mounting base to the motor support channelwith the six screws.

6. Rotate the blower housing 90° to face upwards. Alignthe hole in the side blower housing with the upper slot inthe motor support channel flange and join the two partswith one of the previously removed screws.

7. Attach the two flanges supplied, one to each side ofthe blower housing outlet. Align the holes in the flangewith the holes in the housing and attach with screwssupplied.

8. Drill out the four (4) screw holes in the top panelsecuring the removed cover plate to 1⁄4" inch diameter.

9. Make a 2" long cut in the top panel insulation fromeach corner of the opening toward the sides of the unit toprepare for Step 11.

10. Reposition the top panel on the unit taking care tostraddle the evaporator coil with coil support brackets andto replace all screws.

11. Fold back the top insulation flaps created in Step 9and position the flanges on the blower housing dischargeagainst the top panel. Place the supply plenum flangeover the opening. Align the holes in the flange, gasketand top panel with the blower housing flange holes andsecure with the screws provided. Reposition the topinsulation flaps over the blower housing flanges. Theinsulation must be in place to prevent condensationforming on the top panel.

12. Check that the blower wheel is centered in the inletand discharge of the blower housing. To make anyadjustments, loosen the 4 bolts securing the motor, shiftthe motor as required and refasten the 4 bolts.

13. Place the coverplate removed from the top panelover opening in the front panel and screw in place.

NOTE: Check that all inside cabinet surfaces arecovered with insulation, add insulation if required. Anuninsulated panel will “sweat” and condensate willform on the cabinet.

14. Replace the side access panels.

10

12

10

14

6

13

79

8

11

9

145b

FIGURE 2.9B

GASKETSUPPLY AIRPLENUM FLANGE

MOUNTING SCREWS(4 SUPPLIED)

FIGURE 2.8

AAAAAAAAAAAAAAAAAAAA

2

2

3

4 5a 2

2

FIGURE 2.9A

11

STEP 4: SETTING THE UNITConstruct a platform for the fan coil unit, as shown inFigure 2.10. The platform can be constructed of 2x4(minimum), 2x6, 2x8 and 2x10 lumber, as necessary toachieve proper pitch of 1⁄4" per foot for the condensatedrain line. Figure 2.11 shows the approximate normalallowable run of condensate piping as a function of theframing lumber used for platform construction. Theplatform covering should be 1⁄2" plywood minimum.

Attach vibration isolation pads (supplied with fan coil unit)to platform covering as shown in Fig. 2.8.

Secure the platform to the joist or floor, depending onlocation selected for the fan coil unit. Make sure platformis level.

For locations where the fan coil unit will be suspended,suspend platform from overhead by 1⁄4" threaded rods.

NOTICE: Leave room on sides for servicing.

For installations with a return air box and return air duct,set fan coil unit on the platform with the elliptical openingfacing in the direction of the return air opening. Thesupply air plenum flange should overhang the platform.DO NOT let the flange support the weight of the unit.

Do not secure the unit to the platform, as the weight of the unit will hold it in position.

STEP 5: CONNECTING REFRIGERANTLINESConnect refrigerant lines from the outdoor condensingunit to the fan coil unit in accordance with its manu-facturer's sizing recommendations for the length of the piping run. Proper line sizing is critical to theoperation of the system. Always use proper brazingprocedures. A trickle flow (2PSI) of dry nitrogen to avoidscale or blockage in the piping system is recommendedwhile brazing. Spacepak also recommends installing asight glass on the liquid line outside of the unit as an aid for accurately charging the system.

30" 25"

4 STRIPS 4" x 30" x 1" THICKPOLYURETHANE FOAM

FOR MODEL ESP-2430D

AIR FLOW1 STRIP 4" x 15" x 1" THICK

POLYURETHANE FOAM

1 STRIP 4" x 9" x 1" THICKPOLYURETHANE FOAM


FOR MODEL ESP-4860D

30"44"

AIR FLOW

30" 34"


FOR MODEL ESP-3642D

AIR FLOW





FIGURE 2.10: MOUNTING PLATFORMS

FIGURE 2.11: CONDENSATE PIPING RUNS

LUMBER SIZE

MAXIMUM HORIZONTAL

2 X 4

8'

2 X 6

16'

2 X 8

24'

2 X 10

32'

12

Refer to Fig. 2.2 & 2.3 for condensate drain location. Allcomponents for the PVC condensate trap are provided ina separate bag with fan coil unit (see Fig. 2.12) andshould be cemented together with PVC pipe cement.

CAUTION: Do not use substitute trap. Do not cut offor alter trap components.

Screw male adapter (see Fig. 2.12) into unit condensateline connection. Assemble and cement remainingcomponents together. Then cement assembly to maleadapter. The 45° elbow provides an offset from beneathunit suction line for assess to clean-out plug.

Run a condensate line from the trap to a suitable drainthat’s in accordance with local codes. Make sure the lineis pitched 1⁄4" per foot.

NOTICE: Never connect condensate line to a closeddrain system. When installing unit in an attic (abovea room ceiling), recommend installing a secondarydrain pan or optional float switch.

STEP 6: INSTALLING THE CONDENSATE TRAP & LINE

SLIP JOINT

PIPE PLUG

SLIP JOINT

BUSHING (WHITE)

CLEAN-OUT TEE

CONDENSATETRAP TUBE

TO DRAIN

MALEADAPTER

45° ELBOW

45° ELBOW

MALEADAPTER

5-3/8"

2-1/4"

FIGURE 2.12: CONDENSATE TRAP ASSEMBLY

STEP 7: WIRING THE UNIT

All electrical and control wiring must be installed inaccordance with the codes listed in Section 1 of this manual. Wiring diagram is provided in Figure 2.13. Aseparate 208/230/60/1 power supply is recommended forthe unit. Use standard 15-amp fuse and 14-gauge wirefrom power supply to unit.

Connect power supply to Terminals L1 (hot) and L2 (hot)on the high voltage terminal block. Connect a ground wireto the equipment ground terminal located next to the highvoltage terminal block.

SUPPLY VOLTAGE208/230/60/1

G

FAN MOTOR

FAN CAPACITOR208V

INPUT

45

FR1

CONTROL BOX

TRANSFORMER

H.VOLTAGET.BLOCK

WHT

BLK

GRD. LEAD TOMOTOR BASE

24VOUTPUT

EQUIP.GRD.

L. VOLTAGET. BLOCK

BLUYEL

BRN

BRN

BLK

BLU

R

AFS13FR2

YEL

WHT

FR

RD

L1

L2

ORG

OUTDOOR UNIT

Y

7

6

5

4

3

2

1

YEL

FS

G

R

Y

FACTORY NEC. CL-1

FACTORY NEC. CL

FIELD NEC CL-1

FIELD NEC CL-2

COOL T'STAT TERM.

1. FAN MOTOR FURNISHED WITHINHERENT THERMAL PROTECTION

2. TO BE WIRED IN ACCORDANCE WITH NATIONAL ELECTRIC CODES(NEC) AND LOCAL CODES.

3. USE COPPER CONDUCTORS ONLY.

4. TRANSFORMER IS WIRED FOR 230VSUPPLY. IF 208V IS USED CHANGE TRANSFORMER PRIMARY WIRING.

NOTES

FR

AFS

FAN RELAY

ANTI-FROST SWITCH

FS FLOAT SWITCH (OPTIONAL)

BN

BLK

BLK

FIGURE 2.13: MODEL ESP-D WIRING SCHEMATIC

DANGER: Turn off electrical power supply beforeservicing. Contact with live electric componentscan cause shock or death.¶installed in accordance

The low voltage transformer in the unit has a 208 volt tapin the primary winding (color coded RED). If unit is to beoperated with 208 volt electrical service, remove the 230volt ORANGE lead from the L2 terminal and connect the208 volt RED lead to the L2 terminal. Be sure to insulatethe end of the unused ORANGE lead.

Locate the room thermostat on a wall near the return airbox, between 40" to 48" from the floor. Connect the low-voltage thermostat wiring from the room thermostat tothe low voltage control block in the unit.

STEP 8: INSTALLING AIR DISTRIBUTION COMPONENTSAll plenum duct and supply tubing runs as well as roomterminator locations must be in accordance with airdistribution system requirements listed in Section 1 ofthis manual. Where taping of joints is required,recommend Polyken # 222 tape or equivalent.

Plenum Duct InstallationAll tees, elbows and branch runs must be a minimum of18” from the fan coil unit or any other tee, elbow orbranch run. Keep all tees and elbows to a minimum tokeep system pressure drop on larger layouts to aminimum. Plenum duct comes in 6-foot sections and maybe cut to length.

Begin installing plenum duct (see Figure 2.14). Forstraight or branched plenum run cut off the female end of a plenum duct section. In the case of a bull head tee (see Unit No. 1 in Figure 1.3 on page 5) cut off the male end of a plenum duct section.Then insert duct into fan coil unit receiving collar. Push duct in tight to form snug joint, flatten the sheet metal tabs against the duct and insert flat head pins. Remove paper backingon rectangular foam pieces and place over pins head.Tape the unit/plenum joint securely. To prevent airleakage and condensation, wrap and tape in place the 6" wide piece of foil faced fiberglass insulation overthe taped joint. Be sure insulation is pushed up againstthe unit.

Continue to assemble plenum duct, making sure shiplapjoints (see Figure 2.15) are snug and taped securely.Remember, for the ESP-4860D system, a plenum teemust be installed 18" minimum from the fan coil unitbefore continuing plenum duct run (see air distributionsystem requirements in Section 1 of this manual).

Plenum tee and elbow fittings may be installed at anypoint in the plenum duct run. If installing a fitting at theend of a full plenum section (see Figure 2.16), insertfemale end of fitting into duct. If installing a fitting at a“cut” in the plenum duct (see Figure 2.16), form a field-fabricated flange (11⁄2" wide) in the duct and insert maleend of fitting into duct. Tape the joint securely.

An end cap must be installed at the end of each duct run.The cap contains an insulating cushion which is pushedup tight against the duct end. (If installing end cap at theend of a full plenum section, remove shiplap joint first).Holding cap firmly in place (see Figure 2.17), insert flathead pins through the sheet metal tabs on the end cap.Remove paper backing on rectangular foam pieces andplace over pin heads. Cross-tape cap to the plenum duct,and then tape it circumferentially to the plenum duct.

AAAAAAAAA

REMOVE FLANGE

PREPARING PLENUM

TAB

TAB

INSERTING PLENUM

TAPED JOINT

INSULATED JOINT

FIGURE 2.14: PLENUM INSTALLATION AT UNIT

FIGURE 2.15: PLENUM SHIP-LAP JOINT

13

AT END OF FULLPLENUM SECTION

WHERE PLENUMDUCT IS CUT

FORMFLANGE

AAAA

AAAAA

FIGURE 2.16: PLENUM FITTING INSTALLATION

SHEET METALTABS END CAP

X-TAPE CAPTO DUCT

FIGURE 2.17: PLENUM END CAP INSTALLATION

AAAAAAAAAAA SOUND

ATTENUATING TUBING

THIS RADIUS TOO SHORT

STUD SPACE

TERMINATOR

DRY WALL OR PLASTER

FIGURE 2.18: INCORRECT TUBING INSTALLATION

4" DIA.

5"

5"

FIGURE 2.19: TERMINATOR MEASUREMENTS

Room Terminator & Sound AttenuatingTubing InstallationRoom terminators and pre-assembled sound attenuatingtubing are provided in the Installation Kits.

NOTICE: Do not install terminators in a wall in which a sharp bend in the sound attenuating tubingis required (see Figure 2.18). The result would beunacceptable noise.

In marking location for room terminator (see Figure2.19), the center of the terminator should be 5" from thewall or, when installed in the corner of a room 5" fromboth walls.

After marking location, drill a 1⁄8" diameter hole for outletto be sure there is at least a 2" clearance all around the1⁄8" hole to receive tubing and connector. Adjust directionof hole as needed, to gain this 2" clearance. After allclearances have been checked, take a 4" diameterrotary-type hole saw and cut a hole, using the 1⁄8"diameter hole as a pilot.

Assemble the room terminator to the sound attenuatingtubing by simply fitting the two pieces together andtwisting until tight (see Figure 2.20). If the terminator is tobe used in a floor location, then field fabricate a smallscreen (11⁄2" square; 1⁄4 x 1⁄4 20-gauge galvanized wirescreen) and place screen over opening on the back of theterminator prior to twisting on the kwik-connect (on thesound attenuating tubing).

NOTICE: Do not shorten sound attenuating tubinglength. The result would be unacceptable noise.

Push the free end of the sound attenuating tubingthrough the 4" hole until the two toggle springs on theroom terminator snap into place.

Center the two spring clips on a line parallel to thedirection of the tubing routing from the room terminator(see Figure 2.20). This is important since the weight ofthe tubing will have a tendency to cause a part of theterminator to pull away from the ceiling if the clips andtubing do not run parallel.

Then tighten the screws (attached to the terminator) untilthe terminator is snug against the ceiling or floor. Do not overtighten. For installations with floors or ceilingswhich are thicker than normal, longer toggle screws orspecial mounting plates may be required.

Supply Tubing InstallationKwik-connects, plenum take-off gaskets, plenum take-offs and balancing orifices are provided in the InstallationKits.

Avoid sharp bends in the supply tubing (as well as thesound attenuating tubing). The minimum radius bend is 4" (see Figure 2.21); however, wherever possible, hold toa larger radius.

A

TUBING ROUTING

FIGURE 2.20: POSITIONING ROOM TERMINATOR

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At the plenum in the location selected for attaching thesupply tubing, cut a 2" diameter hole in the plenum withthe Space-Pak plenum hole cutter (see Figure 2.24).

This hole should be cut on the side approximately at a 20° downward angle to eliminate strain on the plenumtake-off when tubing is attached. Rotate the cutter aspressure is applied to force the serrated edge through thealuminum foil and insulation. Remove the hole cut-outfrom the plenum. Make sure there is no “flap” left inside plenum that could block hole during operation.

Place the plenum take-off gasket on the back side of theplenum take-off and insert the assembly into the hole inthe plenum (see FIgure 2.25).

NOTICE: Gasket must be installed to seal plenumtake-off to prevent air leakage.

Orient the plenum take-off to match the curvature of theplenum duct. Hand insert the four plenum take offfasteners one at a time and using the Space-Pak pliers,snap the fasteners into place until they lock in place (seeFigure 2.26).

NOTICE: All four fasteners must be installed toassure air tight fitting between plenum take-off andplenum.

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At the plenum, all supply tubing connections must be aminimum of 18" from any plenum tee, plenum elbow, thefan coil unit or another supply tubing connection.

Individual supply tubing runs must be a minimum of 6-feet, even if the distance between the soundattenuating tubing and plenum is less than 6 feet.

Supply tubing comes in 100-foot sections and may be cut to length with a knife or fine tooth hacksaw.

For each supply tubing run, estimate and cut the lengthof tubing that will be needed between the plenum andsound attenuating tubing. At the open end of the supplytubing which will attach to the sound attenuating tubing,install a kwik-connect (see Figure 2.22). First, push backthe cover and the insulation exposing the inner core.Second, twist a kwik-connect into the inner core. Third,pull down the insulation and cover, and tuck it into thedeep groove on the back of the kwik-connect. Fourth,wrap the connection securely with tape.

When finished, simply twist together (see Figure 2.23)the kwik-connect on the sound attenuating tubing, andwrap the connection securely with tape.

After attaching the supply tubing to the sound attenuatingtubing, bring the open end of the tubing to the plenum.

4" MINIMUM RADIUS

FIGURE 2.21: MINIMUM TUBING BEND

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FIGURE 2.22: KWIK-CONNECT INSTALLATION

FIGURE 2.23: CONNECTING TUBING

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20°

FIGURE 2.24: CUTTING HOLE IN PLENUM

PLENUM

GASKET

FIGURE 2.25: TAKE-OFF INSTALLATION

In accordance with your calculations as to requirementsfor balancing orifices, mount the orifice in the outlet of theplenum take-off (see Figure 2.27), prior to attaching thesupply tubing.

Next, install a kwik-connect in the open end of the supplytubing, using the same procedures as before, and twisttogether kwik-connects on supply tubing and plenumtake-off. Wrap connection securely with tape.

Return Air Box & Duct InstallationRemove the return air grill from the return air box andremove the air filter from the return air grill.

Insert the return box from below for ceiling installation (orfrom the front for wall installations) and fasten with fourscrews through holes provided on the long side of thebox. (see Figure 2.28).

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PLENUM

FASTENER

GASKET

PLENUM TAKE-OFF

GASKET

PLENUM TAKE-OFF

PLENUM

FASTENER

1. HAND INSERT FASTENER INTO PLENUM TAKE-OFF 2. WITH PLIERS, SNAP FASTENER INTO PLACE UNTIL IT LOCKS IN PLACE

FIGURE 2.26: PLENUM TAKE-OFF FASTERNER INSTALLATION

FIGURE 2.27: ORIFICE INSTALLATION

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RETURN AIRBOX

RETURN AIRFILTER GRILL

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FIGURE 2.28: RETURN AIR BOX INSTALLATION

Remove the grill and the filter from the grill frame.Insert the frame into the box and mount in place with thescrews provided through a hole at each corner of theframe. Finally, place the air filter into the frame andreplace the grill. Turn the latches a quarter turn to lock the grill in place. Slide a clamp band (provided with returnair box) over one end of the return air duct. Place that end over the elliptical flange on the fan coil unit (seeFigure 2.29). Move the clamp over the flange and tightenso the clamp holds the return air duct securely to theflange.

Follow the same procedures to attach the return air ductto the return air box (see Figure 2.29).

Winter Supply Shut-Off InstallationSimply snap winter supply shut-offs into the roomterminator openings (see Figure 2.30).Wrap the return airfilter in a plastic bag and reinstall it to block the return airopening. Winter supply shut-offs prevent moisture fromcollecting in ductwork during winter months. Be sure toremove the plastic bag and all supply shut-offs beforeoperating the system.

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ROOM TERMINATOR

WINTERSUPPLYSHUT-OFF

FIGURE 2.30: WINTER SUPPLY SHUT-OFF

FIGURE 2.29: RETURN AIR DUCT INSTALLATION

SEQUENCE OF OPERATIONWhen power is turned on and thermostat fan switch is set to ON and the cooling indicator is set to OFF, theindoor fan motor is energized through the normally opencontact FR1 of the FR fan relay in about 30 seconds.The outdoor unit is off.

When power is turned on and thermostat fan switch is set to ON or AUTO and the cooling indicator to COOL the indoor and outdoor units will start through thenormally open contacts FR1 and FR2 of the FR fan relay.

AUTO position on the thermostat will stop and start yoursystem when the temperature setting is satisfied.The ONposition on the thermostat will stop the outdoor unit onlywhen the temperature setting is satisfied and the indoorunit will continue to run, recirculating indoor air.

The fan coil unit is equipped with a protective devicecalled an anti-frost control which will automatically stopthe outdoor unit (while the indoor unit continues to run) if ice accumulates on the indoor unit evaporator coilcausing abnormal operating conditions. When theaccumulated ice has melted, the anti-frost control willrestart the outdoor unit.

If fan coil unit is equipped with an optional float switch,the condensing unit will automatically shut down if thedrain pan is full of water (condensate) and not draining.The fan coil unit will continue to operate. When the waterlevel in the drain pan drops, the system will continuenormal operation.

PRIOR TO START-UP 1. Check all electrical connections for tightness.

2. Check air filter has been installed in return air box orfilter box.

3. Remove all winter supply shut-offs and store them in asafe place.

STEP 9: INITIAL SYSTEM START UP &OPERATION1. Place thermostat fan switch in ON position and coolingindicator in OFF position. In about 30 seconds, indoorunit blower will start.

2. Check blower operation for excess noise or vibration.

3. Check entire distribution system for leakage and applyadditional tape where necessary.

SECTION 3: START-UP & OPERATION 4. Check that system static pressure is within acceptablelimits (minimum 1.0" W.C. - maximum 1.5" W.C.). Staticreadings must be taken in the plenum a minimum of 18"(or after the tee on ESP-4860D systems) from the fan coilunit, plenum tees or elbows but before any supply run.

5. Check that blower motor amp draw compares with fan coil unit rating plate. Amp draw shown on plate is the FLA of motor (not the actual running amps) and willvary with the pressure and voltage.

6. Place the thermostat cooling indicator in COOLposition, which will start the outdoor unit. Let the systemrun at least 30 minutes to stabilize operating conditions.

7. For outdoor unit start-up, follow manufacturer’sinstructions.

8. Check that temperature drop across evaporator coil in the indoor unit is between 20°F to 28°F.

9. Verify that system refrigerant is correct by one of thefollowing methods listed in order of preference bySpacepak.

A. Check the super heat leaving the evaporator coilagainst the corresponding suction pressure from theschrader fitting at the fan coil unit which can be accessedthrough the service panel. Superheat value should bebetween 9° and 12°F.

B. If a sight glass has been installed on the liquid line atthe air handler check for the presence of flashing.

CHARGING COOLING ONLY SYSTEMSAfter start-up, allow the system to operate for approxi-mately 30 minutes in order to establish stable operatingconditions. Check that the temperature drop across the evaporator coil is 20°F to 30°F. Do not attempt toadjust the charge at ambient temperatures below 65°F.

1. Check refrigerant charge is correct by checking thesuper heat leaving the evaporator coil against the corre-sponding suction pressure from the schrader fiting at thefan coil unit, which can be accessed through the servicepanel. Superheat value should be between 9° and 12°F. Ifa sight glass has been installed on the liquid line at the airhandler check for the presence of flashing.

2. Determine superheat from Figure 3.1.

3. If the superheat is too high, add refrigerant gas to thesuction line service port. Watch pressure gauge andthermometer for correct superheat.

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The Space-Pak system has been designed to provideyears of trouble-free performance in normal installations.Examination by the homeowner at the beginning of eachcooling season, and in mid-season should assurecontinued, good performance. In addition, the systemshould be examined by a qualified service professional atleast once every year.

BEFORE EACH COOLING SEASON1. Check and clean air filter. The air filter is permanenttype. Remove and clean thoroughly with soap solutionand water.

2. Check fan coil unit. Turn off unit power disconnectswitch and remove service access panels.

a. Inspect evaporator coil and blower wheel for build-up of dust and dirt. Clean with solvent and/ or water asnecessary.

b. Replace service access panels and turn on unit power disconnect switch.

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NOTE: Do not introduce refrigerant liquid to systemthrough suction port. Liquid in the suction line maydamage the compressor.

4. If superheat is too low, slowly bleed refrigerant fromsuction line service port into an appropriate refrigerantrecovery device. Watch pressure gauge andthermometer for correct superheat.

CAUTION: Releasing refrigerant gas into theatmosphere is a criminal offense.

It is important that the system be properly charged toavoid an overcharged system, but also to ensure that thesystem operates as efficiently as possible and deliversfull capacity.

SECTION 4: MAINTENANCE 3. Check that unit condensate drain is clear and freerunning, and plug is in cleanout.

4. For outdoor condensing unit, follow manufacturer’smaintenance instructions.

5. Follow “System Start-Up & Adjustments” procedures in Section 3 of this manual.

IF SYSTEM FAILS TO OPERATE1. Check that thermostat switch is set for proper mode of operation and is set below room temperature.

2. Check that outdoor unit is operating.

3. Check for tripped circuit breaker or blown fuse at eitherthe main fuse box or at unit disconnect box on or near the condensing unit. Replace blown fuse with same sizeand type.

FIGURE 3.1: R-22 SUPERHEAT TABLE

Measured Corresponding Superheat Values (F)Suction Saturation 6 8 10 12 14 16 18 20

Pressure (PSIG) Temperature (F) Measured Suction Line Temperatures (F)

60 34 40 42 44 46 48 50 52 5462 35 41 43 45 47 49 51 53 5564 37 43 45 47 49 51 53 55 5766 38 44 46 48 50 52 54 56 5868 40 46 48 50 52 54 56 58 6070 41 47 49 51 53 55 57 59 6172 42 48 50 52 54 56 58 60 6274 44 50 52 54 56 58 60 62 6476 45 51 53 55 57 59 61 63 6578 46 52 54 56 58 60 62 64 6680 48 54 56 58 60 62 64 66 6885 51 57 59 61 63 65 67 69 7190 54 60 62 64 66 68 70 72 7495 56 62 64 66 68 70 72 74 76

100 59 65 67 69 71 73 75 77 79

REF. NAME OF PART PART NO. ESP-2430D ESP-3642D ESP-4860DNO.

1 Anti-Frost Control BM-7353 1 1 1

2

Drain Pan Assembly BM-7354 1



3

Coil Assembly BM-7357 1



4

Expansion Valve 27-3163 1



5 Transformer BM-2528 1 1 1

6

Motor 27-3236 1

Motor 27-3237 1

Motor 27-3238 1

7Blower Wheel 27-8032 1

Blower Wheel 27-8033 1 1

8 Plenum Ring Assembly BM-7360 1 1 1

9 Terminal Block (L.V.) 27-3051 1 1 1

10 Terminal Block (H.V.) 27-3056 1 1 1

11 Access Panel BM-7361 1 1 1

12 Fan Relay 27-3322 1 1 1

13 Float Switch (Optional) BM-6917 1 1 1

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3

411

1

13678

2

L1L2

1 2 3 4 5 6 7

9

10 12

5

FIGURE 4.1: MODEL ESP-D GENERAL ASSEMBLY

LIMITED WARRANTYCentral Air Conditioning Products

The “Manufacturer” warrants to the original owner at the original installation site that the Central AirConditioning Products (the “Product”) will be free from defects in material or workmanship for a period not toexceed one (1) year from the startup or eighteen (18) months from date of shipment from the factory, whicheveroccurs first. If upon examination by the Manufacturer the Product is shown to have a defect in material orworkmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of theProduct which is shown to be defective.

This limited warranty does not apply:a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally

damaged, has not been installed, maintained or operated in accordance with the furnished writteninstructions, or has been altered or modified in any way.

b) to any expenses, including labor or material, incurred during removal or reinstallation of the defectiveProduct or parts thereof.

c) to any workmanship of the installer of the Product.

This limited warranty is conditional upon:a) shipment, to the Manufacturer, of that part of the Product thought to be defective. Goods can only be

returned with prior written approval from the Manufacturer. All returns must be freight prepaid.b) determination, in the reasonable opinion of the Manufacturer, that there exists a defect in material or

workmanship.

Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty withrespect to such repaired or replaced part beyond the stated warranty period.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED,AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED ANDEXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLEIN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATUREWHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT ORANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINALOWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICHMAY VARY BY EACH JURISDICTION.

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