Engineered air EngA CU Series User manual

IOM-14 Feb 06 R4

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

FOR

CU SERIES

CONDENSING UNITS

INDOOR AND OUTDOOR MODELS

UNIT MODEL NO. _________________

UNIT SERIAL NO. _________________

SERVICED BY: ___________________

TEL. NO: ________________________

CANADIAN

HEAD OFFICE

AND FACTORY

USA

HEAD OFFICE

AND FACTORY

CANADIAN

EASTERN FACTORY

1401 HASTINGS CRES. SE

CALGARY, ALBERTA

T2G 4C8

Ph: (403) 287-4774

Fx: 888-364-2727

32050 W. 83rd STREET

DESOTO, KANSAS

66018

Ph: (913) 583-3181

Fx: (913) 583-1406

1175 TWINNEY DRIVE

NEWMARKET, ONTARIO

L3Y 5V7

Ph: (905) 898-1114

Fx: (905) 898-7244

SALES OFFICES ACROSS CANADA AND USA

Retain instructions with unit and maintain in a legible condition.

Please give model number and serial number when contacting

factory for information and/or parts.

www.engineeredair.com

ACU MANUAL

IOM-14 2 of 46 Feb 06 R4

TABLE OF CONTENTS

YOU HAVE RESPONSIBILITIES TOO ...................................................................................................................................3

INTRODUCTION ................................................................................................................................................................3

SAFETY PRECAUTIONS ......................................................................................................................................................3

WARRANTY .......................................................................................................................................................................4

PARTS................................................................................................................................................................................4

RECEIVING.........................................................................................................................................................................5

TEMPORARY STORAGE .....................................................................................................................................................5

INSTALLATION...................................................................................................................................................................5

CODES...............................................................................................................................................................................6

In Canada:.........................................................................................................................................................................6

In USA: ..............................................................................................................................................................................6

MINIMUM CLEARANCE FOR SERVICE AND TO COMBUSTIBLES IN INCHES (mm)............................................................6

QUALIFIED INSTALLER.......................................................................................................................................................7

COMPONENT LOCATIONS.................................................................................................................................................7

PIPING RECOMMENDATIONS...........................................................................................................................................8

PIPE SELECTION PROCEDURE .........................................................................................................................................17

PIPING MATERIALS AND PROCEDURES ..........................................................................................................................23

CLEARANCE FOR CONDENSER AIR FLOW .......................................................................................................................25

LIFTING............................................................................................................................................................................26

MOUNTING.....................................................................................................................................................................26

SHIPPING MATERIALS.....................................................................................................................................................27

ASSEMBLY.......................................................................................................................................................................27

PIPING, ELECTRICAL OR CONTROL SERVICE CONNECTIONS...........................................................................................27

ELECTRICAL INSTALLATION.............................................................................................................................................28

BEFORE START-UP ..........................................................................................................................................................29

START-UP CHECK LIST.....................................................................................................................................................29

INITIAL START-UP............................................................................................................................................................33

CHARGING ......................................................................................................................................................................33

OPERATION.....................................................................................................................................................................34

SHUTDOWN PROCEDURE...............................................................................................................................................35

MAINTENANCE ...............................................................................................................................................................36

ELECTRICAL .....................................................................................................................................................................36

BELT ADJUSTMENT .........................................................................................................................................................36

BEARING SETSCREW TORQUES.......................................................................................................................................38

FILTERS............................................................................................................................................................................41

CONTROLS ......................................................................................................................................................................42

OUTDOOR AIR INTAKES, MIXING SECTIONS AND DAMPERS..........................................................................................42

REFRIGERATION..............................................................................................................................................................42

TROUBLESHOOTING CHART...........................................................................................................................................45

ACU MANUAL

IOM-14 3 of 46 Feb 06 R4

YOU HAVE RESPONSIBILITIES TOO

This installation, operation and maintenance manual cannot cover every possibility, situation or

eventuality. Regular service, cleaning and maintaining the equipment is necessary. If you are not capable

of performing these tasks, hire a qualified service specialist. Failure to perform these duties can cause

property damage and/or harm to the building occupants and will void the manufacturers’ warranty.

INTRODUCTION

Engineered Air units are high quality products designed and manufactured to provide many years of

trouble-free operation. We recommend that this manual be read thoroughly to ensure proper installation,

efficient operation and proper maintenance of this equipment. The submittal record is considered to be

part of the Installation, Operation and Maintenance Manual. Please report any omissions to the national

service manager.

SAFETY PRECAUTIONS

Read, understand and follow the complete manual before beginning the installation, including all safety

precautions and warnings.

Warning:

Improper installation, adjustment, alteration, service or maintenance can cause

property damage, injury or death. Read the installation, operating and maintenance

instructions thoroughly before installing or servicing this equipment.

Warning:

This unit is connected to high voltages. Electrical shock or death could occur if

instructions are not followed. This equipment contains moving parts that can start

unexpectedly. Injury or death could occur if instructions are not followed. All work

should be performed by a qualified technician. Always disconnect and lock out power

before servicing. DO NOT bypass any interlock or safety switches under any

circumstances.

ACU MANUAL

IOM-14 4 of 46 Feb 06 R4

WARRANTY

LIMITED WARRANTY ENGINEERED AIR will furnish without charge, F.O.B. factory, freight collect,

replacement parts for, or repairs to products covered herein which prove defective in material or

workmanship under normal and proper use for a period of twelve (12) months from the initial start-up or

eighteen (18) months from the date of shipment, whichever expires sooner, provided the customer gives

ENGINEERED AIR written notice of such defects within such time periods and provided that inspection by

ENGINEERED AIR establishes the validity of the claim and all pertinent invoices have been paid in full. The

repairs or replacements will be made only when the complete product(s) or part(s) claimed to be defective

are returned to ENGINEERED AIR or a depot designated by ENGINEERED AIR, transportation charges

prepaid. Repairs or replacements as provided for by this paragraph shall constitute fulfillment of all

ENGINEERED AIR's obligations with respect to this warranty. The refrigerant charge is not included in any

part of this warranty. This warranty does not apply to any products or parts thereof that have been subject

to accident, misuse or unauthorized alterations, or where ENGINEERED AIR's installation and service

requirements have not been met.

The foregoing warranty is in lieu of all other warranties, express or implied. ENGINEERED AIR specifically

disclaims any implied warranty of merchantability and/or fitness for purpose. Under no circumstances

shall ENGINEERED AIR be liable to, nor be required to indemnify, Buyer or any third parties for any claims,

losses, labour, expenses or damages (including special, indirect, incidental, or consequential damages) of

any kind, resulting from the performance (or lack thereof) of this Agreement or the use of, or inability to

use the goods sold hereunder, including, but not limited to, damages for delay, temporary heating/cooling

costs, loss of goodwill, loss of profits or loss of use. Furthermore, the parties agree that the Buyer's sole

remedy under this Agreement shall be limited to the limited warranty set forth in the preceding paragraph

relating to the repair or replacement of any defective goods. Under no circumstances shall any claim or

award against ENGINEERED AIR exceed the original contract price whether awarded through arbitration,

litigation or otherwise.

ENGINEERED AIR Warranty is void if:

1. The unit is not installed in accordance with this manual.

2. The start-up and operation of the unit is not performed in accordance with this manual.

3. The unit is operated in an atmosphere containing corrosive substances.

4. The unit is allowed to operate during building construction.

PARTS

Warning:

Any replacement part must be of equivalent listing or certification and be functionally

equivalent. The replacement part must meet the original’s specification in terms of

functionality including certifications, timing, input and output range, accuracy and

operation.

Failure to replace parts or components with equivalent parts can cause property

damage, injury or death.

ACU MANUAL

IOM-14 5 of 46 Feb 06 R4

1. Motors:

Motor manufacturers have service centers that will repair or replace motors as required.

2. Parts Other Than Motors:

Contact the nearest Engineered Air sales office or factory. Be sure to include Model Number, Serial

Number, date of installation and nature of failure along with the description of the parts required.

Some parts may not be stocked items that must be made or ordered.

RECEIVING

Refer to the back of the packing slip for receiving unit instructions.

On receipt of the unit, check for damage. Inspect protective covers for punctures or other signs that there

may be internal damage. Remove protective covers and check for internal damage. Replace covers if the

unit is not being assembled or installed at this time. Open access doors and check for internal damage.

Close access doors when the inspection is complete. If damage is found follow the instructions on the

packing slip.

On receipt of the unit, check electrical characteristics (see rating plate) to make sure the unit voltage is

compatible with that available for the unit. All parts for field installation are listed on the shipping order

form.

TEMPORARY STORAGE

If a unit is to be stored prior to installation the following precautions are required:

•Store in a well drained area that will not accumulate surface water.

•Store in an area where the unit will not get damaged.

•The entire perimeter and any full height cross members of the unit must be supported by a level

surface and the supporting surface must be adequate for supporting the entire weight of the unit.

•All protective coverings that were provided for shipping must be in place.

•Protect indoor units from rain and snow.

INSTALLATION

Warning:

This unit is not rated for hazardous locations and cannot be installed in areas requiring

any hazardous location rating.

Caution:

All wiring, piping and fuel line installation must be completed by qualified persons in

accordance with all federal, state, provincial and/or local codes.

ACU MANUAL

IOM-14 6 of 46 Feb 06 R4

Note: Installation shall be in accordance with this manual and all other associated component and

control Installation, Operation and Maintenance Manuals.

CODES

In Canada:

1. The installation of this unit shall be in accordance with the latest edition of the Canadian Electrical

Code, Part 1 –C.S.A. Standard C22.1, Provincial and Local Codes, and in accordance with the local

authorities having jurisdiction.

2. This unit shall be electrically grounded in accordance with the latest edition of the Canadian

Electrical Code, Part 1 –C.S.A. Standard C22.1, Provincial and Local Codes, and in accordance with

the local authorities having jurisdiction.

3. The installation of this unit shall be in accordance with the latest edition of the Mechanical

Refrigeration Code, C.S.A. Standard B52, Provincial and Local Codes, and in accordance with the

local authorities having jurisdiction.

4. The installation of this unit shall be in accordance with all other National, Provincial and Local

Codes, and in accordance with the local authorities having jurisdiction.

In USA:

1. The installation of this unit shall be in accordance with the latest edition of the National Electrical

Code (ANSI/NFPA 70), State and Local Codes and in accordance with the local authorities having

jurisdiction.

2. This unit shall be electrically grounded in accordance with the latest edition of the National

Electrical Code (ANSI/NFPA 70), State and Local Codes and in accordance with the local authorities

having jurisdiction.

3. If the unit has not been provided with an electric disconnect switch, one of adequate ampacity

shall be installed in accordance with Article 430 of the National Electrical Code (ANSI/NFPA 70).

4. The installation of this unit shall be in accordance with the latest edition of the ANSI/ASHRAE

Standard 15 - Safety Code for Mechanical Refrigeration, ANSI/ASME SEC VIII - Boiler and Pressure

Vessel Code, ANSI/ASME B31.S ASME Code for Pressure Piping and Refrigeration Piping, State and

Local Codes and in accordance with the local authorities having jurisdiction.

5. The installation of this unit shall be in accordance with all other National, State and Local Codes,

and in accordance with the local authorities having jurisdiction.

MINIMUM CLEARANCE FOR SERVICE AND TO COMBUSTIBLES IN INCHES (mm)

MODEL

COMBUSTIBLE CLEARANCE

SERVICE CLEARANCE

TOP

FRONT

BACK

SIDE

BOTTOM

SERVICE SIDE

CONTROL

PANEL †

1"(25)

1" (25)

1"(25)

36" (915)

42" (1067)

†- As required by the Canadian Electrical Code or the National Electrical Code.

For Safety and Service, the minimum clearances must be observed.

ACU MANUAL

IOM-14 7 of 46 Feb 06 R4

Note:

The minimum clearance for proper air flow is 60” (1500 mm) to obstructions and 96” (2400

mm) to an adjacent condensing unit or air conditioning unit.

QUALIFIED INSTALLER

To complete the installation, an air-conditioning contractor experienced and qualified in system piping is

required. The contractor is responsible for the design, selection and installation of the refrigeration

specialties and refrigerant piping for this equipment. The following information is intended to provide

general information and guidelines for the successful installation of this equipment.

For detailed information about installation practices consult ASHRAE handbooks, ANSI/ASME Codes,

ANSI/ASHRAE Safety Code for Mechanical Refrigeration, CAN/CSA B52 Mechanical Refrigeration Code and

any local authorities having jurisdiction.

NOTE:

Component selection, piping design and installation of the air conditioning system are the

responsibility of the installing contractor. This manual is designed to provide general

guidelines and recommendations only. It is not intended to be a complete manual for air

conditioning design.

COMPONENT LOCATIONS

Consider the issues related to your installation and the relative location of the components.

Locate the condensing unit as close as practical to the evaporator section. Shorter refrigerant piping will

always result in a lower refrigerant charge, greater reliability and longer system life.

Considerations for different arrangements.

Three arrangements are possible:

1. Condensing unit above evaporator

2. Condensing unit is on the same level as evaporator.

3. Condensing unit below evaporator.

1. Condensing Unit Above The Evaporator

In this orientation, the suction gas must travel up a riser to get to the condensing unit. The suction riser

must be correctly sized to ensure proper oil return. Traps are required at the bottom of all risers. Double

risers may be required on systems with tandem compressors or unloaders. Refer to ASHRAE Refrigeration

Handbook for information on double risers.

The liquid line will have a vertical drop in this orientation and gravity will aid in taking the liquid to the

evaporator section. The liquid refrigerant will GAIN pressure at the rate of one half a psig per foot of

vertical drop. If the drop is considerable, this pressure gain may affect the sizing of the TX valve.

ACU MANUAL

IOM-14 8 of 46 Feb 06 R4

2. Condensing Unit At The Same Elevation As The Evaporator.

Select suction and liquid lines from the appropriate tables. Horizontal suction lines should slope down in

the direction of flow with a 1:200 slope.

3. Condensing Unit Located Below The Evaporator.

This arrangement should only be considered when other options are not available.

With the compressor below the evaporator, oil return in the suction line is helped by gravity. Horizontal

runs are sloped down in the direction of flow with a 1:200 slope.

The liquid must travel upwards, and there are several issues that must be addressed. As the liquid travels

upward, it must fight gravity and it will LOSE pressure at the rate of 0.5 psig per vertical foot. Adequate

subcooling is required to counteract the pressure losses due to vertical rise, plus the pressure drop due to

friction losses and accessories. Standard subcooling for most condensing units is 10°F, (5°C).

In the off cycle, all liquid refrigerant in the line will drain down to the condenser by gravity. When the

system restarts, time is required for the liquid refrigerant to fill the liquid line and travel to the TX valve. A

low-pressure control bypass timer may be required, to allow time for liquid to reach the TX valve, and

prevent the system from short-cycling during startup.

An EngA Intercooler (optional) may be installed at the TX valve to improve performance and reduce flash

gas during fluctuating load conditions.

Consider installing an additional liquid line sight glass at the TX valve to ensure that a solid column of liquid

reaches the TX valve. This simple step at installation time can save many hours of troubleshooting if there

is a flash gas issue.

PIPING RECOMMENDATIONS

Underground Piping

Caution:

Underground Piping is not recommended.

Improper installation of a condensing unit with underground piping will result in

equipment failure.

Consult Factory on all systems with underground refrigerant piping.

Underground piping will void compressor warranty unless specifically authorized by the

factory.

In the off cycle, the refrigerant charge will migrate to the coldest location. Typically, ground temperatures

are cooler than air temperatures, and the underground piping becomes the coolest location. In this case

the refrigerant charge will migrate to underground piping.

When the compressor starts, any liquid refrigerant in the suction line will enter the compressor causing

both diluted oil and slugging. Either condition will reduce the life of the compressor.

ACU MANUAL

IOM-14 9 of 46 Feb 06 R4

Suction line accumulators and crankcase heaters are required on all systems with underground piping.

Consult factory for guidance.

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PIPING CONNECTION SIZES

Refrigerant piping must be selected to meet the conditions required for your specific installation. The

tubing connection sizes on the condensing unit and/or evaporator may or may not be the correct size for

your specific application.

NOTE:

DO NOT select tubing sizes based on the size of the connection stubs.

The correct tubing size for your installation must be checked and selected for each and every

job.

Traps

It is recommended that traps be installed on all suction or discharge gas risers.

Suction Line

The temperature penalty is a measure of capacity loss due to pressure drop in the tubing. Select the

suction line to have a maximum temperature penalty of 2°F (1°C). Higher temperature penalties will

reduce both system capacity and efficiency. See Refrigeration Table 3.

Use Refrigeration Table 2 Piping Guidelines to select the suction line size. Suction lines are selected at

design load conditions, and must be rechecked at minimum load conditions to ensure oil return. Tandem

compressor systems and systems with unloaders must be re-checked at the unloaded condition to ensure

oil return.

Should a compromise be required between oil return and pressure drop, oil return must always have

priority.

•Slope the suction line down with a 1:200 grade in the direction of flow to help oil return.

•Suction lines should be insulated to prevent unnecessary heat gain.

•Install oil traps at the bottoms of all risers.

Liquid Line

Select the line size using piping tables.

Liquid lines should have a maximum refrigerant velocity of 350 feet per minute (1.78 m/s) to avoid liquid

hammer.

Select pressure drop for a temperature penalty of less than 2°F. (1°C)

If a liquid line travels through a warm area, such as a boiler room, insulate the line to prevent heat gain.

Ensure the temperature penalty does not exceed the subcooling provided by the condensing unit.

A sight glass should be installed at the TX valve to ensure the valve is receiving a solid column of liquid if

adequate subcooling is a concern. An EngA Intercooler may be ordered and installed to help reduce the

effects of inadequate subcooling.

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