SECTION 1: INTRODUCTION
SpacePak System Design.......................................
Code Compliance.....................................................
Air Distribution Requirements...................................
Model Number Description........................................
Air Distribution Components.....................................
Warranty Information....................................
Shipment of Unit.......................................................
SECTION 2: SYSTEM INSTALLATION
Step 1: Locating The Unit.........................................
Step 2: Cutting Return Air Opening..........................
Step 3: Attaching Supply Air Plenum Adaptor..........
Step 4: Setting The Unit............................................
Step 5: Connecting Refrigerant Lines.......................
Step 6: Installing The Condensate Trap & Line.........
2
2
2
2
3
Back Page
5
6
8
9
11
11
12
Step 7: Wiring The Unit.........................................
Step 8: Installing Air Distribution Components......
SECTION 3: START UP & OPERATION
Sequence Of Operation........................................
Prior To Start-Up...................................................
System Start-Up & Adjustments...........................
Charging Cooling Only Systems...........................
Factors Affecting the Balance of the System........
SECTION 4: MAINTENANCE
Before Each Cooling Season................................
If System Fails To Operate....................................
Troubleshooting Guide..........................................
Service/Troubleshooting Form..............................
Parts List...............................................................
12
14
18
18
18
18
19
20
20
21-25
26
27
IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 (413) 564-5530/FAX (413) 564-5815
IN CANADA: 7555 TRANMERE DRIVE, MISSISSAUGA, ONTARIO, L5S 1L4 (905) 672-2991/FAX (905) 672-2883
Central Air Conditioning Series
2 to 5 Tons
Fan Coil Unit/Air Supply
Components
MODEL
ESP-G SYSTEM
INSTALLATION,
OPERATION
& MAINTENANCE
MANUAL
ESPG2-709
W30-WG0482-01
7/09
2
SPACEPAK SYSTEM DESIGN
SpacePak is a hi-velocity central air conditioning system
which utilizes a conventional outdoor condensing unit
matched with the indoor Model ESP-G fan coil unit to
provide conditioned air through the specially-designed,
pre-fabricated, pre-insulated flexible duct system. The
system and its basic components operate the same as in
any conventional air-to-air cooling system.
The SpacePak 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; 926,673
and Canadian Patents: 891,292; 923,935; 923,936.
CODE COMPLIANCE
Fan coil unit installation must conform to the requirements of the local authority having jurisdiction or, in the
absence of such requirements, to the National Board of
Fire Underwriters regulations. Fan coil unit meets ETL
listing requirements.
All electrical wiring must be in accordance with the
National Electrical Code ANSI/NFPA No. 70-latest
edition and any additional state or local code requirements. If an external electrical source is utilized, the fan
coil unit, when installed, must be electrically grounded.
NOTICE: It is a requirement of the International
Mechanical Code (307.2.3) to install a secondary
drain or an auxiliary drain pan where damage to any
building components will occur as a result of
overflow from the equipment drain pan or stoppage
in the condensate drain piping from a cooling or an
evaporator coil. Follow local code requirements.
AIR DISTRIBUTION SYSTEM COMPONENT
REQUIREMENTS
Air distribution components installation must conform to
the requirements of local authority having jurisdiction or,
in the absence of such requirements, to the National
Fire Protection Association 90A or 90B.
Do not begin the installation of the system without
performing a load calculation to determine heat gain,
system layout and material take-off. If a layout plan is not
already available and room terminator requirements
determined, then refer to the SpacePak Application
Manual, SP9, to complete this information. A description
of air distribution system components is shown in
Figure 1.1.
Section 1: INTRODUCTION
The following terms are used throughout this
manual to bring attention to the presence of potential
hazards or to important information concerning the
product:
Indicates an imminently hazardous
situation which, if not avoided, will result in death,
serious injury or substantial property damage.
Indicates an imminently hazardous
situation which, if not avoided, could result in
death, serious injury or substantial property damage.
Indicates an imminently hazardous
situation which, if not avoided, may result in
minor injury or property damage.
NOTICE: Used to notify of special instructions on
installation, operation or maintenance which are
important to equipment but not related to personal
injury hazards.
SpacePak - Model Number Description
1 2 3 4 5 6 7 8 9 10
UT CA SE CT RT
1,2,3, - Unit Type [UT] 8 - Series [SE]
ESP - Evaporator DX Fan Coil Unit G - "G" series
4,5,6,7 - Capacity [CA] 9 - Cabinet Type [CT]
2430 - 24,000 to 30,000 BTU/Hr. (2-2
1
/2tons) H - Horizontal
3642 - 36,000 to 42,000 BTU/Hr. (3-31/2tons)
4860 - 48,000 to 60,000 BTU/Hr. (4-5 tons) 10 - Refrigerant Type [RT]
4 - R410A
3
RETURN AIR BOX (SPC-1D, AC-RBF-3, SPC-3D):
Each includes filter grill with metal frame, permanent
filter, and 2 clamp bands. SPC-1D is for ESP-2430G.
AC-RBF-3 is for ESP-3642G and SPC-3D is for ESP-4860G.
RETURN AIR DUCT (SPC-4,5, & 6): Flexible, 10 feet
long with round shape. SPC-4 (15" dia.) for ESP-2430G.
SPC-5 (19" dia.) for ESP-3642G and SPC-6 (24" dia.) is
for ESP-4860G.
PLENUM ADAPTOR: 9" round OR 10" X 10" square
metal component to attach plenum duct to fan coil unit.
PLENUM DUCT & COMPONENTS: May be 9" round
sheet metal or 10" X 10" (O.D.) square, fiberboard duct
types as specified by the installing contractor. Above
layout is shown as an illustrative assembly reference
only.
R6 SUPPLY TUBING (AC-ST6-100): Flexible, R6 insulated, 2" I.D. and 3-
1
⁄4" O.D. Each section is 100 feet long.
R8 SUPPLY TUBING (AC-ST8-75): Flexible, R8 insulated,
2" I.D. and 5-3⁄8" O.D. Each section is 75 feet long.
INSTALLATION KITS: Contains a specified amount
of sound attenuating tubes, kwik-connects, terminator
plates (incl. spring clips & screws), winter supply air
shut-offs and a balancing orifice set to complete
installation of room outlets. Supplied in (2) and (5) outlet
boxed quantities.
PLENUM TAKE-OFF KIT: Contains a specific amount of
plenum take-offs, gaskets and fasteners to complete
installation of room outlets. Take-offs available for round
sheet metal or square fiberboard duct as specified by
installing contractor. Supplied in (2) and (5) outlet boxed
quantities.
KWIK CONNECT WALL ELBOW (AC-KCWE): To allow
for wall terminations in 2" X 4" stud spaces.
SECONDARY DRAIN PAN: Specifically sized for
SpacePak horizontal fan coil units. Constructed of
durable polyethylene. Fan coil unit sets directly on top
and can be installed with threaded rod.
PLIERS (SPC-72): To assure full setting of all clips
(fasteners) in plenum take-off (not shown).
PLENUM HOLE CUTTER (SPC-71-10): To cut 2" hole
in fiber board for plenum take-off installation (not
shown).
FIGURE 1.1: AIR DISTRIBUTION SYSTEM COMPONENTS
4
Plenum Duct
The plenum duct can be run in practically any location
accessible for the attachment of the supply tubing (see
suggested layouts in Figure 1.2). The plenum is normally located in the attic or basement, and it is usually more
economical to run the plenum where it will appreciably
shorten the lengths of two or more supply runs.
In some two-story split level homes, it may be advantageous to go from one level to another with the plenum
duct. Whenever necessary, either between floors or
along the ceiling, the small size of the plenum makes it
easy to box in.
PLENUM
PLENUM
FAN COIL
UNIT
PLENUM
FAN COIL
UNIT
PLENUM
FAN COIL
UNIT
PLENUM
FAN COIL
UNIT
FAN COIL
UNIT
FIGURE 1.2: PLENUM/TUBING LAYOUT EXAMPLES (FOR GUIDANCE ONLY)
The fan coil unit is designed to operate with a total external static pressure of 1.5 inches of water column (minimum 1.2 - maximum 1.5). Excessive static pressure
increases the air flow in individual runs and may cause
some or all terminators to be noisy.
For systems designed with a bullhead tee installed as on
Unit No. 1 (Figure 1.3), the best results are obtained if not
more than 60% of the total number of system outlets are
attached to any one branch of the tee. For systems with a
branch tee installed as on Unit No. 2 (Figure1.3), not more
than 30% of the total number of system outlets should be
attached to the perpendicular branch of the tee.
The larger system capacities (ESP-3642/4860G) are
effected more by higher system static pressure than the
smaller systems. Installation of the plenum tee closer
than the minimum indicated in Fig. 1.3 will reduce
performance of the system. No supply runs should be
installed between unit outlet and this tee. Static readings
on system should be taken before tee.
Supply Tubing
In the case of two-story or split-level applications, supply
tubing may run from one story to another. It is small
enough to go in stud spaces, but this is often difficult in
older homes because of hidden obstructions in stud
spaces. It is more common to run the supply tubing from
the attic down through second story closets to the first
story terminators.
Supply tubing runs in the corners of the second story
rooms can be boxed in and are hardly noticeable since
overall diameter is only 31⁄4".
Room Terminators
Terminators should be located primarily in the ceiling or floor
for vertical discharge or high on a wall for horizontal
discharge. Installation of horizontally discharged terminators
is assisted with the SpacePak 90˚ wall elbow (see page 15).
Two excellent spots for horizontal discharge are in the soffit
area above kitchen cabinets (see Figure 1.4) and in the top
portion of closets (see Figure 1.5).
Terminators should always be out of normal traffic
patterns to prevent discharge air from blowing directly on
occupants. And they should not be located directly above
shelves or large pieces of furniture. Outside wall or
corner locations are recommended if the room has more
than one outside wall. Locating terminators away from
interior doors prevents short cycling of air to the return air
box.
SHIPMENT OF UNIT
Each fan coil unit is shipped in a single carton. Packed
with the unit, there are vibration isolation pads, a condensate trap assembly and a factory installed primary
float switch.
UNIT NO. 1
FIGURE 1.3: ESP-3642/4860G INSTALLATIONS
FIGURE 1.4: TERMINATOR IN SOFFIT AREA
FIGURE 1.5: TERMINATOR IN CLOSET TOP AREA
5
FAN COIL UNIT
NO MORE THAN
MINIMUM 24"
UNIT NO. 2
FAN COIL UNIT
MINIMUM 24"
60% OF CAPACITY
ON ONE SIDE
30% MAX. OF CAPACITY
ROOM
TERMINATOR
ROOM
TERMINATOR
SUPPLY
TUBING
Model
System
capacity
(Nom. Tons)
Suction
Line (O.D.)
Liquid
Line (O.D.)
Cond.
Drain
(FPT)
Return
Inlet
(Dia.)
Connections
Recommended
Condensing Unit
Nominal
Capacity
(MBH)
Min
SEER
ESP-2430G
ESP-3642G
ESP-4860G
2 - 2-1/2
3 - 3-1/2
4 & 5
Electrical
Characteristics
208-230/60/1
208-230/60/1
208-230/60/1
7/8"
7/8"
7/8"
3/8"
3/8"
3/8"
3/4"
3/4"
3/4"
15"
19"
24"
24 to 30
36 to 42
48 to 60
13+
13+
13+
Model
System
capacity
(Nom. Tons)
Air Volume
@ 1.5" W.C.
(SCFM)
Motor
HP
F. L .
Amps
No. of
Rows
Deep
Blower
Holding
Charge
(Dry
Nitrogen)
Flow
Control
Type
Ship.
Wt.
(lbs)
ESP-2430G
ESP-3642G
ESP-4860G
2 - 2-1/2
3 - 3-1/2
4 & 5
550 1/3
1/2
1
PSC
PSC
PSC
1.8
2.8
5.3
6
6
6
7 psi Exp. Valve
Exp. Valve
Exp. Valve
120
144
171
850
115 0
Motor
Type
Coil
Wheel Dia.
and
Width
9" x 5"
9" x 6-3/8"
9" x 5"
6
SECTION 2: SYSTEM INSTALLATION
NOTICE: Before proceeding with the installation, we
recommend reading through this section of the
manual for an overall understanding of the air
conditioning fan coil unit and air distribution system
component installation procedures.
STEP 1: LOCATING THE UNIT
The fan coil unit may be installed in an unconditioned
space (as long as it is protected from the weather) such
as an attic, garage or crawlspace...or a conditioned
space such as a basement, closet or utility room (see
dimensions in Figures 2.2 and 2.3).
The fan coil unit is shipped in a horizontal air flow
arrangement, but can be easily field-converted to a
vertical air flow arrangement as detailed on page 9 and
Figures 2.8 and 2.9.
When selecting a location, consider the locations (as
shown in Figures 2.4, 2.5 and 2.6) of the return air box;
routing of the plenum duct, supply tubing, refrigerant lines,
condensate drain line; and all recommended clearances
(see Figures 2.2 and 2.3).
FIGURE 2.1: MODEL ESP-F SPECIFICATIONS
FIGURE 2.2: UNIT DIMENSIONS AND CLEARANCES (inches)
7 psi
7 psi
7
FIGURE 2.4: TYPICAL UNIT INSTALLATION
FIGURE 2.5: HORIZONTAL AIR FLOW UNIT INSTALLATION
FIGURE 2.3: CONNECTION LOCATIONS AND ASSEMBLED PLENUM ADAPTOR DIMENSIONS
SUPPLY AIR OUTLET
CLAMP BAND
FLEXIBLE RETURN
DUCT (90 BEND)
CLAMP BAND
48" MIN.
(ALTERNATE LOCATION)
SPACEPAK FAN
COIL UNIT
SUPPLY AIR OUTLET
RETURN AIR BOX
WITH GRILL & FILTER
2 Ft.
MAX.
PLATFORM (FIELD ERECTED
AS SHOWN IN STEP 4)
SUPPORT
RETURN AIR BOX
90°
14 Ft. MAXIMUM FLEXIBLE
RETURN DUCT
SUPPORT
FAN COIL UNIT
SUPPLY AIR
90°
PLATFORM (FIELD ERECTED
AS SHOWN IN STEP 4)
8
STEP 2: CUTTING RETURN AIR OPENING
If joists are on 16" centers, the 141/2" width of the return
air box should fit between successive joists. Where
joists run in the opposite direction, or to properly center
the return, it may be necessary to cut joists and install
headers.
For all wall return applications, cut the return air opening
to accomodate the return air box according to the same
dimensions. Remember, location of opening must allow
for a 90° bend in the return air duct.
Check the opening for proper fit of the return air box. Do
not install the return air box until the installation of the
entire SpacePak system is completed, if you want to fit
materials up through this hole.
FIGURE 2.7: RETURN AIR BOX FRAME DIMENSIONS
SUPPORT
FIGURE 2.6: VERTICAL AIR FLOW UNIT INSTALLATION
Select exact location for return air box. Avoid installing
box in dining room, living room, kitchen, etc., unless
return air duct can be installed with at least two 90°
bends (accomplished by splicing two return air ducts
together.)
For attic installations to raise fan coil unit up through
opening, cut return air opening 14
1
/2" wide by 27" long for
the ESP-2430G, 141/2" wide by 311/2" long for the ESP3642G* and 141/2" wide by 361/2" long for the ESP-4860G.
These openings will accomodate the return air box with
sufficient frame lip to cover the opening (see Figure 2.7).
*NOTICE: The return air panel must be removed from
the ESP-3642G unit to fit through hole cut out.
A
14-5/16"
Measure return air box dimension
"A" to determine length of opening.
Height = 14-5/16"
DWG0045
RETURN AIR BOX
90°
14 Ft. MAXIMUM FLEXIBLE
RETURN DUCT
2 Ft.
MAX.
90°
SUPPORT
PLATFORM (FIELD ERECTED
AS SHOWN IN STEP 4)
SUPPLY
AIR
FAN COIL UNIT
9
STEP 3: ATTACHING SUPPLY AIR PLENUM ADAPTOR
NOTICE: If unit is to be located in the attic and
installed through ceiling joists, attach supply plenum
adaptor in attic.
A. HORIZONTAL DISCHARGE:
Refer to Figure 2.3 and duct installation instructions
supplied with fan coil unit.
B. TO CONVERT TO VERTICAL DISCHARGE:
Refer to Figure 2.8 & 2.9
Tools required: 1/4", 5/16", 3/8", 7/16" box wrenches and nut
drivers, 5/32" Allen wrench, utility knife & Malco S-3 offset
hand seamer (3" duct-bill pliers).
Field supplied: latex caulk, UL classified duct liner
adhesive (or equivalent).
NOTICE: An Electric Heat Module cannot be installed
after unit has been field converted to vertical supply
air discharge (due to resulting blower housing
obstruction).
Refer to Figure 2.8 for Steps 2 to 8a.
1. Place unit horizontally on a flat raised surface.
2. Remove all side access panels, return air panel and
cover plate from top panel.
3. Remove top panel by removing top/center screw
from electric control box and panel screws.
4. Remove (4) screws securing front panel flange to
blower housing.
5. Remove sealant around discharge opening.
6. Remove (3) remaining screws from electrical control
box. Set box aside.
7. Remove (2) screws attaching blower housing to
motor support channel flange.
8a. Remove (6) screws attaching motor mounting base
to motor support channel.
Refer to Figure 2.9 for Steps 8b to 18.
8b. Shift motor mounting base (and blower housing)
backtoward coil to second set of mounting lugs on
motor support channel. Rotate blower housing up 90°.
Reattach base with screws.
9. Cut insulation from discharge air location on top
panel (opening dimensions shown in Figure 2.3).
Insert cut piece into opening. Apply adhesive per
manufacturer's instructions. Attach cover plate to
front of unit.
10. Bend both flanges 90° into cabinet using 3" duct-bill
pliers. Pliers should engage full jaw depth (1-1/4") and
be centered on flange.
11. Insert blower housing into top panel. Reattach panel
to unit.
12. Align hole in blower housing with lower slot in motor
support channel flange. Attach housing to flange with
(1) previously removed screw.
13. Align (4) holes in top panel flange with holes in
blower housing. Attach with removed screws.
14. Assure blower wheel is centered in inlet and
discharge of blower housing. If required, adjust by
loosening (4) bolts securing motor. Shift motor and
refasten. For blower wheel adjustments, loosen set
screw (not shown), shift wheel and refasten.
15. Apply latex caulk to seal between blower housing
and top panel.
16. Reinstall electrical control box.
17. Place supply air plenum adaptor over discharge
opening. Align holes in plenum adaptor, gasket and top
panel. Secure with screws provided with adaptor.
NOTICE: Check that all inside cabinet surfaces are
covered with insulation, add insulation if required. An
uninsulated panel will “sweat” and condensate will
form on the cabinet.
18. Replace all panels and screws.
10
FIGURE 2.9
FIGURE 2.8
11
STEP 4: SETTING THE UNIT
Construct a platform for the fan coil unit, as shown in
Figure 2.10. The platform can be constructed of 2x4
(minimum), 2x6, 2x8 and 2x10 lumber, as necessary to
achieve proper pitch of 1⁄4" per foot for the condensate
drain line. Figure 2.11 shows the approximate normal
allowable run of condensate piping as a function of the
framing lumber used for platform construction. The
platform covering should be 1⁄2" plywood minimum.
Attach vibration isolation pads (supplied inside fan coil
unit) to platform covering as shown in Fig. 2.10.
Secure the platform to the joist or floor, depending on
location selected for the fan coil unit. Make sure platform
is 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 opening
facing in the direction of the return air box. The supply air
plenum adaptor should overhang the platform. DO NOT
let the adaptor 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 REFRIGERANT
LINES
Connect refrigerant lines from the outdoor condensing
unit to the fan coil unit in accordance with its manufacturer's sizing recommendations for the length
of the piping run. Proper line sizing is critical to the
operation of the system. Always use proper brazing
procedures. A trickle flow (2PSI) of dry nitrogen to avoid
scale or blockage in the piping system is recommended
while brazing. SpacePak also recommends installing a
sight glass on the liquid line outside of the
unit as an aid for accurately charging the system.
FIGURE 2.10: MOUNTING PLATFORMS SHOWN WITH VIBRATION ISOLATION STRIPS
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'
4 STRIPS 4" x 30" x 1" THICK
POLYURETHANE FOAM
FOR MODEL ESP-2430G
5 STRIPS 4" x 30" x 1" THICK
POLYURETHANE FOAM
FOR MODEL ESP-3642G
7 STRIPS 4" x 30" x 1" THICK
POLYURETHANE FOAM
FOR MODEL ESP-4860G
30"
30"
30"
AIR FLOW
AIR FLOW
AIR FLO
25"
1 STRIP 4" x 15" x 1" THICK
POLYURETHANE FOAM
1 STRIP 4" x 9" x 1" THICK
POLYURETHANE FOAM
34"
44"
W
1 STRIP 4" x 15" x 1" THICK
POLYURETHANE FOAM
1 STRIP 4" x 14" x 1" THICK
POLYURETHANE FOAM
1 STRIP 4" x 15" x 1" THICK
POLYURETHANE FOAM
1 STRIP 4" x 16" x 1" THICK
POLYURETHANE FOAM
12
NOTICE: It is a requirement of the International
Mechanical Code (307.2.3) to install a secondary drain
or an auxiliary drain pan where damage to any building
components will occur as a result of overflow from the
equipment drain pan or stoppage in the condensate
drain piping from a cooling or an evaporator coil.
Follow local code requirements
Refer to Fig. 2.2 for primary and secondary condensate
drain locations. Components for the PVC condensate
trap are provided in a separate bag with fan coil unit (see
Fig. 2.12) and should be cemented together with PVC
pipe cement.
Do not use substitute trap. Do not cut
off or alter trap components.
Screw male adapter (see Fig. 2.12) into unit’s primary
condensate drain connection. Assemble and cement
remaining components together. Then cement assembly
to male adapter. The 45° elbow provides an offset from
beneath unit suction line for access to clean-out plug.
Run a condensate line from the trap to a suitable drain
that’s in accordance with local codes. Make sure the line
is pitched 1⁄4" per foot.
NOTICE: The secondary drain connection requires
field supplied components to complete installation.
Follow local code requirements.
NOTICE: Never connect condensate line to a closed
drain system.
STEP 6: INSTALLING THE CONDENSATE TRAP & LINE
FIGURE 2.12: CONDENSATE TRAP ASSEMBLY
STEP 7: WIRING THE UNIT
All electrical and control wiring must be installed in
accordance with the codes listed in Section 1 of this
manual. Wiring diagram is provided in Figure 2.13. A
separate 208-230/60/1 power supply is recommended for
the unit. Use standard 15-amp fuse and 16-gauge wire
from power supply to unit.
Connect power supply to Terminals L1 and L2 on the high
voltage terminal block. Connect a ground wire to the
equipment ground terminal located next to the high voltage terminal block.
Turn off electrical power supply
before servicing. Contact with live electric components can cause shock or death.
The low voltage transformer in the unit has a 208 volt tap
in the primary winding (color coded RED). If unit is to be
operated with 208 volt electrical service, remove the 230
volt ORANGE lead from the L2 terminal and connect the
208 volt RED lead to the L2 terminal. Be sure to insulate
the end of the unused ORANGE lead.
Locate the room thermostat on a wall near the return air
box, between 40" to 48" from the floor. Connect the lowvoltage thermostat wiring from the room thermostat to the
low voltage control block in the unit.
Connect low voltage from air handler to condensing unit
as shown in figure 2.13.
Set DIP switches according to application. See page 14,
SpacePak G Series Control DIP switch settings.
STEP 8: INSTALLING AIR DISTRIBUTION COMPONENTS
All plenum duct and supply tubing runs as well as room
terminator locations must be in accordance with air
distribution system requirements listed in Section 1 of
this manual. Where taping of joints is required, UL181
approved tape is required.
Plenum Duct Installation
All tees, elbows and branch runs must be a minimum of 24"
from the fan coil unit or any other tee, elbow or branch run.
Keep all tees and elbows to a minimum to keep system
pressure drop on larger layouts to a minimum.
NOTICE: Refer to duct installation instructions supplied with fan coil unit or follow manufacturers
instructions supplied with other duct system types.
1
*
NOTE: PIPE SECTIONS ARE FIELD SUPPLIED.
SECOND 3/4" MALE ADAPTER SUPPLIED FOR OVERFLOW CONN
*
SEE NOTE
2
3/4'' P-TRAP ASS'Y KIT
ITEM
DESCRIPTION
MALE ADAPTER, 3/4''
1
2
ELBOW 45
TEE, 3/4''
3
4
3/4'' X 1/2'' BUSHING
5
1/2'' PLUG
P-TRAP, 3/4''
6
????
5
4
3
WG0127B
6
, 3/4 ''
ECTION
FIGURE 2.13: WIRING DIAGRAM
13
14
SpacePak G Series Control Dip Switch Settings
12 3456
SpacePak G Series Control Indicator LEDs
Power Indicator
The Power indicator will blink to indicate that the control is operational.
F
an Prove Indicator
The Fan Prove indicator will illuminate when there is power to the fan and the optional damper is in the open position.
Note: The Fan Prove Terminal will also energize with 24VAC when the above conditions are met.
F
ault Indicator
Fault Flash Codes:
Float Switch 1 Flash
Anti-Frost Switch 2 Flashes
Fan Prove Fault 3 Flashes
Note: All Flash Codes are latched until power is cycled, even if the fault is cleared. The Float Switch requires power
to be cycled to resume operation.
CWC
HWC
HP
OB
PWC
SpacePak G Series
Control Variable
Time Delay Settings
Fan On Delay for
Water Coil Heat Demands
Adjustable from
0 - 2 Minutes
FC
Cooling Water Coil Settings
Cooling Wat er Coil Prese nt
No Cooling Wa ter Coil Prese nt
No Heat Pump Pr esent
Potable Water Circulation Settings
Switch 1
Heat Pump Settings
Switch 3
Heat Pump Present
Switch 5
ON
OFF
Heating Water Coil Settings
Heating Water Coil Present
No Heati ng Water Coil Present
Changeover Valve Settings
Energized in Cooling Mode
Energized in Heating Mode
Switch 2
Switch 4
Fan Circulation Settings
Switch 6
ON
OFF
0
Fan Off Delay for ALL
Heating and Cooling Cycles
Adjustable from
0 - 2 Minutes
0
2
2
SOUND
FIGURE 2.17: INCORRECT TUBING INSTALLATION
Room Terminator & Sound Attenuating
Tubing Installation
Room terminators and pre-assembled sound attenuating
tubes are provided in the Installation Kits.
NOTICE: Do not install terminators in a wall in
which a sharp bend in the sound attenuating tube is
required (see Figure 2.17). The result would be
unacceptable noise
..
OPTION: Using a SpacePak Kwik Connect Wall Elbow
(Model Number: AC-KCWE) addresses this condition
(see Figure 2.18).
In marking location for room terminator (see Figure
2.19), the center of the terminator should be
approximately 5" from the wall or, when installed in the
corner of a room 5" from both walls.
After marking location, drill a 1⁄8" diameter hole for outlet.
Verify there is at least 2" for tubing assembly clearance
all around this hole by visual inspection or inserting a
bent piece of wire to feel for obstructions. Adjust direction
of hole as needed, to gain this 2" clearance. After all
clearances have been checked, take a 4" diameter
rotary-type hole saw and cut a hole, using the 1⁄8"
diameter hole as a pilot.
Assemble spring clips to terminator plate with screws
provided in installation kit. Tighten clips until they are
close to the thickness of the material they are being
mounted to.
Assemble the room terminator to the sound attenuating
tubing by simply fitting the two pieces together and
twisting until tight (see Figure 2.20). If the terminator is to
be used in a floor location, then field fabricate a small
screen (1
1
⁄2" square; 1⁄4x 1⁄420-gauge galvanized wire
screen) and place screen over opening on the back of the
terminator prior to twisting on the kwik-connect (on the
sound attenuating tube).
NOTICE: Do not shorten sound attenuating tube
length. The result would be unacceptable noise.
Push the free end of the sound attenuating tube through
the 4" hole until the two toggle springs on the room terminator snap into place.
Center the two spring clips on a line parallel to the
direction of the tubing routing from the room terminator
(see Figure 2.20). This is important since the weight of
the tubing will have a tendency to cause a part of the
terminator to pull away from the ceiling if the clips and
tubing do not run parallel.
Then tighten the screws (attached to the terminator) until
the terminator is snug against the ceiling or floor. Do
not overtighten. For installations with floors or ceilings
which are thicker than normal, longer toggle screws or
special mounting plates may be required.
FIGURE 2.20: POSITIONING ROOM TERMINATOR
15
INS
ULATION
3/8 NO
MINAL
SHEET
ROCK
SOUND
ATTENUATOR
3.
500 0.
625
3/16 GAGAP
FOR
APPL
ICATIONS W
ITH
THICKER
WALL
BOARD,
REM
OVE MATERIAL FROM
THIS AR
EA TO ALLO
W FOR
PROPER FIT.T.
FIGURE 2.18: INSTALLATION WITH KWIK
CONNECT WALL ELBOW
FIGURE 2.19: TERMINATOR MEASUREMENTS
ATTENUATING
TUBE
DRY WALL
OR PLASTER
THIS RADIUS
TOO SHORT
TERMINATOR
STUD SPACE
FOR
APP
THICKER
RE
THIS A
PROPER
ICATIONS
WAL
OVE MATERIAL FROM
BOARD
EA TO ALL
SHEET
SOUND
ITH
W FOR
3/16
IN
ROCK
500
625
ATTENUATOR
ULA
3/8
MINAL
SPL-0050-A
4" DIA.
5"
5"
TUBING ROUTING
After attaching the supply tubing to the sound attenuating
tube, bring the open end of the tube to the plenum.
To cut a hole in the plenum, refer to duct installation
instructions supplied with fan coil unit. Sheet metal duct
requires a 21/16" hole.
Remove the hole cut-out from 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 the
plenum take-off and insert the assembly into the hole in
the plenum (see Figure 2.25).
NOTICE: Gasket must be installed to seal plenum
take-off to prevent air leakage.
Orient the plenum take-off to match the curvature of the
plenum duct. Hand insert the four plenum take off
fasteners one at a time such that each clip reaches the
interior of the duct. Using the SpacePak pliers, snap the
fasteners into place until they lock in place (see Figure
2.26).
NOTICE: All four fasteners must be installed to
assure air tight fitting between plenum take-off and
plenum.
16
Supply Tubing Installation
Kwik-connects and balancing orifices are provided in the
Installation Kits. Plenum take-offs, gaskets and fasteners
are supplied in the separate plenum take-off kit.
Avoid sharp bends in the supply tubing (as well as the
sound attenuating tubing). The minimum radius bend is
4" (see Figure 2.21); however, wherever possible, hold to
a larger radius.
At the plenum, all supply tubing connections must be a
minimum of 18" from any plenum tee, plenum elbow or
the fan coil unit.
Individual supply tubing runs must be a minimum of
6-feet, even if the distance between the sound
attenuating tubing and plenum is less than 6 feet.
Supply tubing comes in 100-foot sections (R8 tubing
comes in 75-foot sections) and may be cut to length with
a knife or fine tooth hacksaw.
For each supply tubing run, estimate and cut the length
of tubing that will be needed between the plenum and
sound attenuating tube. At the open end of the supply
tubing a kwik-connect will be installed (see Figure 2.22).
First, push back the cover and the insulation exposing
approximately 4" of the inner core. Fold in any tails or
frays that may be present after cutting the supply tubing.
Second, hand compress the corrugations until they are
densely compacted 1
1
/2" to 2" from the open end of the
supply tube. Third, thread kwik-connect into the inner
core until snug. Fourth, pull the insulation and cover forward and tuck it into the deep groove on the back side
of the kwik-connect. Fifth, wrap the connection securely
with UL181 approved tape.
When finished, simply twist together (see Figure 2.23)
the kwik-connect on the sound attenuating tube, and
wrap the connection securely with tape.
TWIST
FIGURE 2.22: KWIK-CONNECT INSTALLATION
FIGURE 2.25: TAKE-OFF INSTALLATION
FIGURE 2.23: CONNECTING TUBING
4" MINIMUM RADIUS
FIGURE 2.21: MINIMUM TUBING BEND
PLENUM
GASKET
In accordance with your calculations as to requirements
for balancing orifices, mount the orifice in the outlet of the
plenum take-off (see Figure 2.27), prior to attaching the
supply tubing.
Next, install a kwik-connect in the open end of the supply
tubing, using the same procedures as before, and twist
together kwik-connects on supply tubing and plenum
take-off. Wrap connection securely with tape.
Return Air Box & Duct Installation
Remove the return air grill from the return air box and
remove the air filter from the return air grill.
Insert the return box from below for ceiling installation (or
from the front for wall installations) and fasten with four
screws through holes provided on the long side of the
box. (see Figure 2.28).
17
GASKET
FIGURE 2.26: PLENUM TAKE-OFF FASTENER INSTALLATION
FIGURE 2.27: ORIFICE INSTALLATION
RETURN AIR
BOX
RETURN AIR
FILTER GRILL
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 the
screws provided through a hole at each corner of the
frame. Finally, place the air filter into the frame and
replace the grill. Turn the latches a quarter turn to lock
the grill in place. Slide a clamp band (provided with return
air box) over one end of the return air duct. Place that
end over the elliptical flange on the fan coil unit (see
Figure 2.29). Move the clamp over the flange and tighten
so the clamp holds the return air duct securely to the
flange.
Follow the same procedures to attach the return air duct
to the return air box (see Figure 2.29).
Winter Supply Shut-Off Installation
Simply insert winter supply shut-offs into the room
terminator openings (see Figure 2.30). Wrap the return
air filter in a plastic bag and reinstall it to block the return
air opening. Winter supply shut-offs prevent moisture
from collecting in ductwork during winter months. Be sure
to remove the plastic bag and all winter supply shut-offs
before operating the system.
FIGURE 2.30: WINTER SUPPLY SHUT-OFF
FIGURE 2.29: RETURN AIR DUCT INSTALLATION
PLENUM TAKE-OFF
GASKET
PLENUM TAKE-OFF
PLENUM
PLENUM
FASTENER
1. HAND INSERT FASTENER INTO PLENUM TAKE-OFF 2. WITH PLIERS, SNAP FASTENER INTO PLACE UNTIL IT LOCKS IN PLACE
FASTENER
ROOM
TERMINATOR
WINTER
SUPPLY
SHUT-OFF
SEQUENCE OF OPERATION
When power is turned on and thermostat fan switch is
set to ON and the cooling indicator is set to OFF, the
indoor fan motor is energized in approximately 2 minutes.
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.
AUTO position on the thermostat will stop and start your
system when the temperature setting is satisfied. The
ON position on the thermostat will stop the outdoor unit
only when the temperature setting is satisfied and the
indoor unit will continue to run, recirculating indoor air.
The fan coil unit is equipped with a protective device
called an anti-frost control which will automatically stop
the outdoor unit (while the indoor unit continues to run)
if ice accumulates on the indoor unit evaporator coil
causing abnormal operating conditions. When the
accumulated ice has melted, the anti-frost control will
restart the outdoor unit.
The fan coil unit is equipped with primary float switch,
and the system will automatically shut down if the drain
pan is full of water (condensate) and not draining. The
system requires service.
PRIOR TO START-UP
1. Check all electrical connections for tightness.
2. Check air filter has been installed in return air box or
filter box.
3. Remove all winter supply shut-offs and store them in a
safe place.
SYSTEM START-UP & ADJUSTMENTS
1. Place thermostat fan switch in ON position and cooling indicator in OFF position. In about 2 minutes, indoor
unit blower will start.
2. Check blower operation for excess noise or vibration.
3. Check entire distribution system for leakage and apply
additional tape where necessary.
SECTION 3: START-UP & OPERATION
4. Check that system static pressure is within acceptable
limits (minimum 1.2" W.C. - maximum 1.5" W.C.). Static
readings must be taken in the plenum a minimum of 18"
from the fan coil unit, plenum tees or elbows but before
any supply run.
a. If greater than 1.5" W.C. add additional supply runs.
b. If less than 1.2" W.C. check the return air filter is
clean and return duct is not collapsed or kinked.
c. Check supply air plenum for leaks.
d. If more supply runs than recommended are used,
check that balancing orifices are in place.
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 will
vary with the pressure and voltage.
6. Place the thermostat cooling indicator in COOL
position, which will start the outdoor unit. Let the system
run at least 30 minutes to stabilize operating conditions.
7. For outdoor unit start-up, follow manufacturer’s
instructions.
8. Check that temperature drop across evaporator coil
in the indoor unit is between 20°F to 28°F.
NOTICE: Do not introduce refrigerant liquid to system
through suction port. Liquid in the suction line may
damage the compressor.
NOTICE: Before adding refrigerant to system verify
Item #4 in “System Start-up & Adjustment” section
has been performed.
9. Verify that system refrigerant is correct by measuring
subcooling at liquid service port. Subcooling should be
10°F to 13°F.
10. Check the super heat leaving the evaporator coil
against the corresponding suction pressure from the
schrader fitting at the fan coil unit. Superheat value
should be between 9° and 12°F.
11. If a sight glass has been installed on the liquid line at
the air handler check for the presence of flashing. If
flashing is occuring, check and adjust subcooling by
adding refrigerant.
CHARGING COOLING ONLY SYSTEMS
After start-up, allow the system to operate for approximately 30 minutes in order to establish stable operating
conditions. Check that the temperature drop across
the evaporator coil is 20°F to 30°F. Do not attempt to
adjust the charge at ambient temperatures below 65°F.
18
19
1. Check refrigerant charge by measuring liquid subcooling.
Subcooling should be approximately 10°F to 13°F. If a
sight glass has been installed on the liquid line at the fan
coil unit check for the presence of flashing.
2. If the subcooling is below 10°F, add refrigerant gas to
the suction line service port. Watch pressure gauge and
thermometer for correct subcooling. It should be
approximately 10°F to 13°F.
3. If subcooling is too high, slowly bleed refrigerant from
suction line service port into an appropriate refrigerant
recovery device. Watch pressure gauge and
thermometer for correct subcooling (10˚F to 13˚F).
Releasing refrigerant gas into the
atmosphere is a criminal offense.
FACTORS AFFECTING THE BALANCE OF
THE SYSTEM
A. Room Terminators (Outlets): Based on the
equipment selected, determine the recommended
number of fully open outlets from Figure 3.1.
FIGURE 3.1
NOMINAL
TONNAGE
2
2-1/2
3
3-1/2
4
5
MODEL
ESP-2430G
ESP-2430G
ESP-3642G
ESP-3642G
ESP-4860G
ESP-4860G
A
12
15
18
21
26
30
MINIMUM RECOMMENDED
NUMBER OF FULLY OPEN OUTLETS
1. The minimum or recommended number of outlets
means fully open outlets. Any outlet having an orifice
would be only a percentage of an outlet.
2. For systems with average supply tubing lengths of 15
feet or less, use column A. For systems with supply
tubing lengths greater than 15 feet, use column B.
NOTICE: The number of outlets and average length of
the supply tubing has a significant effect on the overall system performance. It is highly recommended
that the adjustment factors outlined in the SpacePak
Application Manual are accounted for prior to any
installation.
B. Orifice Combinations: Should orifices be required to
balance the system (installed at plenum take-off),
refer to the combinations listed in Figure 3.2.
FIGURE 3.2
*For a room with more than two (2) terminals, combinations of
the above may be used to achieve the desired fractional
number.
C.Supply Tubing Length: An outlet with a supply tubing
length of 15 feet is considered one, fully opened outlet. For
other lengths refer to Figure 3.3 for adjustment factors.
FIGURE 3.3
2" SUPPLY TUBING LENGTH ADJUSTMENT FACTOR CHART
RUN 6' 8' 10' 12' 15' 20' 25' 30'
FACTOR .85 .88 .90 .94 1.0 1.1 1.25 1.50
B
14
18
21
25
28
35
DESIRED NUMBER
OF TERMINALS*
.5
.65
.85
1.00
1.15
1.30
1.50
1.65
1.70
1.80
1.85
1.95
2.00
TERMINAL - ORIFICE
COMBINATION
(1) .5
(1) .35
(1) .15
(1)
(1) .5 + (1) .35
(2) .35
(1) .35 + (1) .15 or (1) + (1) .5 or (3) .5
(1) + (1) .35 or (2) .5 + (1) .35
(2) .15
(2) .35 + (1) .5
(1) + (1) .15
(3) .35
(2)
The SpacePak system has been designed to provide
years of trouble-free performance in normal installations.
Examination by the homeowner at the beginning of each
cooling season, and in mid-season should assure
continued, good performance. In addition, the system
should be examined by a qualified service professional
at least once every year.
BEFORE EACH COOLING SEASON
1. Check and clean air filter. The air filter is permanent
type. Remove and clean thoroughly with soap solution
and water.
Turn off electrical power supply before
servicing. Contact with live electric
components can cause shock or death.
2. Check fan coil unit. Turn off unit power disconnect
switch and remove service access panels.
a. Inspect evaporator coil and blower wheel for buildup of dust and dirt. Clean with solvent and/ or water as
necessary.
b. Replace service access panels and turn on unit
power disconnect switch.
SECTION 4: MAINTENANCE
3. Check that unit condensate drain is clear and free
running, and plug is in cleanout.
4. For outdoor condensing unit, follow manufacturer’s
maintenance instructions.
5. Follow “System Start-Up & Adjustments” procedures
in Section 3 of this manual.
IF SYSTEM FAILS TO OPERATE
1. Check that thermostat switch is set for proper mode
of operation and is set below room temperature.
2. Check that outdoor unit is operating.
a. Confirm that compressor and fan are operating
properly
b. Confirm voltages to outdoor unit
IF FAN AND COMPRESSOR AT OUTDOOR
UNIT ARE NOT RUNNING
1. Check Fault Indicator. See Flash Codes, page 14.
Float switch fault will stop fan and compressor.
2. Check for tripped circuit breaker or blown fuse at either
the main fuse box or at unit disconnect box on or near
the condensing unit. Replace blown fuse with same size
and type.
3. Review Troubleshooting Guide beginning on page 21
of this manual.
20
TROUBLESHOOTING GUIDE
POSSIBLE CAUSE VERIFICATION SOLUTION
Low Suction Pressure Check blower motor as described on If defective, replace motor.
page 25 in this manual.
Check that filter in return air box is Clean air filter.
clean.
Check system refrigerant charge. Charge to proper subcooling accord-
ing to manufacturer’s instructions.
Check for dirty evaporator coil. Clean evaporator coil.
High Suction Pressure Check for air bubbles in system Charge to proper subcooling accord-
refrigerant. i
ng to condensing unit manufacturer’s instructions. Install sight glass
near indoor unit and monitor.
Check calculated heat gain to be Take necessary action.
sure that equipment is sized properly.
Check for obstructions near Remove obstructions.
condensing unit which could cause
recirculation of air.
Low Head Pressure Check system refrigerant charge. Charge to proper subcooling
according to condensing unit
manufacturer’s instructions.
Check calculated heat gain to be sure Take necessary action.
that equipment is sized properly.
High Head Pressure Check condenser fan motor accord- If defective, replace fan motor.
ing to condensing unit manufacturer’s
instructions.
Check for dirty condensing unit coil. Clean condensing unit coil.
Check system refrigerant charge. Charge to proper subcooling
accordi
ng to condensing unit
manufacturer’s instructions.
Check for dirty evaporator coil. Clean evaporator coil.
Check for obstructions near Remove obstructions.
condensing unit which could cause
recirculation of air.
Check for restricted liquid lines. Remove restrictions and kinks from
lines.
Distribution System Air Leaks Check all joints in air distribution Make sure all joints are air tight.
system. Verify static pressure as described
on page 25 in this manual.
CONDITION: ESP-G & CONDENSING UNITS RUN, BUT COOLING INSUFFICIENT
21
22
POSSIBLE CAUSE VERIFICATION SOLUTION
Thermostat Not Level Check level of thermostat If necessary, level thermostat.
Defective Thermostat With volt meter, check resistance of If resistance, thermostat is O.K.
thermostat contacts. If no resistance, replace thermostat.
Loose Low Voltage Wiring Check all wiring connections for Tighten all loose connections.
tightness.
Defective Low Voltage Transformer Check transformer as described on If defective, replace transformer.
page 25 in this manual.
Inadequate Electrical Service Check electrical service against Replace electrical service with
minimum requirements. adequately sized service.
Flash Code - 1 Flash (Float Switch) Check drain plan and condensate trap. Clean condensate trap.
CONDITION: ESP-G UNIT & CONDENSING UNIT WILL NOT START
POSSIBLE CAUSE VERIFICATION SOLUTION
Shorted Or Broken Wiring Check wiring. If necessary, repair or replace wiring.
Loose Low or High Voltage Wiring Check all wiring connections for Tighten all loose connections.
tightness.
Defective Blower Motor Check motor as described on page 25 If defective, replace motor.
in this manual.
CONDITION: ESP-G UNIT WILL NOT START, BUT CONDENSING UNIT RUNS
POSSIBLE CAUSE VERIFICATION SOLUTION
Defective Thermostat With volt meter, check resistance of If resistance, thermostat is O.K.
thermostat contacts. If no resistance, replace thermostat.
Loose Low Or High Voltage Wiring Check all wiring connections for Tighten all loose connections.
tightness.
If no voltage, check coil for ice. If
ice is present, check air filter, return
air duct & blower motor for air flow.
Flash Code - 2 Flashes With volt meter, check for 24v
(Anti-Frost Switch) at terminal “AFS”. If no ice on coil, check anti-frost
switch for continuity. If no
continuity, replace switch.
If 24v, switches are O.K.
Shorted Or Broken Wiring Check wiring. If necessary, repair or replace wiring.
Condensing Unit Check according to manufacturer’s Repair or replace as directed by
instructions. manufacturer.
CONDITION: ESP-G UNIT RUNS, BUT CONDENSING UNIT WILL NOT START
23
POSSIBLE CAUSE VERIFICATION SOLUTION
Incorrect Low Voltage Connections Check low voltage connections Correct low voltage connections.
against wiring diagram.
Loose Low Voltage Connections Check all wiring connections for Tighten all loose connections.
tightness.
Defective Blower Motor Check motor as described on page If defective, replace motor.
25 in this manual.
CONDITION: ESP-G UNIT WILL NOT START, BUT CONDENSING UNIT CYCLES
POSSIBLE CAUSE VERIFICATION SOLUTION
Blower Motor Check motor as described on page 25 If defective, replace motor.
in this manual.
Check motor amps and compare to If excessive, motor may be
nameplate ratings. overloaded. Check supply duct for
breaks or leaks.
CONDITION: ESP-G UNIT CYCLES, BUT CONDENSING UNIT RUNS
POSSIBLE CAUSE VERIFICATION SOLUTION
Flash Code - 2 Flashes With volt meter, check for 24v at If no voltage, check coil for ice.
(Anti-Frost Switch) terminal “AFS”. If ice is present,
check air filter,
return air duct & blower motor for
air flow.
If no ice on coil, check anti-frost
switch for continuity. If no continuity,
replace switch.
If 24v, switches are O.K.
Thermostat in Wrong Location Check that thermostat is in vicinity of If necessary, relocate thermostat.
return air box.
Loose Low Or High Voltage Wiring Check all wiring connections for Tighten all loose connections.
tightness.
Defective Blower Motor Check motor as described on page 25 If defective, replace motor.
in this manual.
Condensing Unit Check according to manufacturer’s Repair or replace as directed by
instructions. manufacturer.
CONDITION: ESP-G UNIT RUNS, BUT CONDENSING UNIT CYCLES
24
POSSIBLE CAUSE VERIFICATION SOLUTION
High Supply Air Plenum Static Check static pressure as described Check for and add flow restrictors
Pressure on page 25 in this manual. as necessary in supply runs.
If necessary, add additional outlets.
Sound Attenuating Tube Not Check for installation of sound Where necessary, install sound
Installed attenuating tube. attenuating tube.
Tight Radius In Sound Attenuating Check all tubing for tight radius. Where necessary, correct radius.
Tube Or In Supply Tubing
Incorrect Supply Tubing Length Check that all supply tubing runs Where necessary, correct supply
are 9’ minimum (includes 3 ft tubing length.
sound atten. tube).
Improperly Balanced System Check that correct size orifices Properly orifice supply tubing runs.
have been installed.
CONDITION: EXCESSIVE NOISE AT TERMINATOR
POSSIBLE CAUSE VERIFICATION SOLUTION
Air Leak At Supply Air Plenum Check taped joint at adaptor. Tape joint properly.
Adaptor
Insulation at Outlet Not Installed Check for insulation at outlet. Install insulation.
CONDITION: SWEATING AT ESP-G UNIT SUPPLY OUTLET
POSSIBLE CAUSE VERIFICATION SOLUTION
Noisy Blower Motor Assembly Check blower motor assembly. Tighten all fasteners.
Check blower motor for bearing Replace motor.
noise.
Check for loose or damaged blower Tighten or replace blower wheel
wheel. as necessary.
CONDITION: EXCESSIVE VIBRATION AT ESP-G UNIT
POSSIBLE CAUSE VERIFICATION SOLUTION
Return Air Duct Not Installed Check for minimum 90˚ bend in Correct bend in return air duct
Properly return air duct. to minimum 90˚.
Dirty Return Air Filter Remove and inspect. Clean or replace air filter.
CONDITION: EXCESSIVE NOISE AT RETURN AIR GRILL
CHECKING ESP-G BLOWER MOTOR
1. With volt meter, check voltage at terminals L1 and L2
on line voltage terminal block. Voltage should be
±10% of ESP-G unit nameplate rating.
2. Disconnect power to the ESP-G unit at the disconnect
switch.
3. Disconnect motor lead at terminal L2.
4. With an ohmmeter, check continuity between the
disconnected motor lead and terminal “FAN PWR” on
control panel.
a. If continuity, proceed to Step 5 below.
b. If no continuity, feel the motor to see if it is
excessively warm which would indicate the internal over- load may be open. When motor has
cooled, check again to make sure you did not get
a false reading. If no continuity, motor is defective.
5. With an ohmmeter, check each motor lead to ground
to be sure motor is not grounded.
a. If not grounded, proceed to Step 6 below.
b. If grounded, motor is defective.
6. Check capacitor, if capacitor is suspect, replace it with
a capacitor of similar rating of motor operates normally,
make a permanent capacitor replacement.
7. Reconnect all electrical leads, restore electrical services to the ESP-G unit, and place thermostat fan
switch in the ON position.
8. With an ampmeter, check that amp draw compares
with ESP-G unit rating plate. Amp draw shown on
plate is the FLA of motor (not the actual running
amps) and will vary with the pressure and voltage.
CHECKING ESP-G BLOWER
The ESP-G unit is equipped with a time-delayed blower.
Wait two full minutes after turning on power for blower to
start.
1. With a volt meter, check 24v across terminals R and
C on the low voltage terminal block.
a. If read 24v, proceed to Step 2.
b. If no voltage, check low voltage transformer.
2. With a volt meter, check 24v across terminals G and
C on the low voltage terminal block.
a. If read 24v, proceed to Step 3.
b. If no voltage, check thermostat fan circuit.
CHECK ESP-G LOW VOLTAGE TRANSFORMER
1. With volt meter, check for 230v across terminals L1
& L2 on the line voltage terminal block.
a. If reading 230v, proceed to Step 2.
b. if no voltage, check the power supply to the unit.
2. With volt meter, check for 24v across terminal R and
terminal C on the low voltage terminal block.
a. If read 24v, transformer is O.K.
b. If no voltage, replace transformer.
CHECK EXTERNAL STATIC PRESSURE
You can use a U-tube manometer to check the external
static pressure on the duct system.
1. Puncture a 1/4" hole in the plenum duct at least 18"
from the fan coil unit.
2. Insert one manometer tube into the hole until the
end of the tube is flush with the inside wall of the
plenum duct.
3. System static pressure should be between 1.2" and
1.5" W.C.
a. If greater than 1.5" W.C. add additional supply
runs.
b. If less than 1.2" W.C. , check:
I. Return air filter is clean
II. Return air duct has not been collapsed
III. Supply air plenum for leaks
IV. If more supply runs than recommended are
used, check that flow restrictors (orifices)
are in place.
25
26
Customer / Dealer Data:
Name:
Address:
Tel (day) (eve)
Installing Dealer / Contractor:
Name:
Tel:
Equipment Data:
SPACEPAK Model #
ESP / WCSP -
SPACEPAK Serial #
SPACEPAK Date of Installation:
Cond Unit Mfr:
Cond Unit Mod #:
Rated Capacity:
BTUH
; SEER:
Air-side Data:
Total # of outlets: ; Supply tube length: Ft (avg)
(Please sketch duct layout on reverse side of this sheet, noting all fittings
and distances, including return duct size / length)
Air Filter: Size (LxHxD)
Type (pleated, etc):
Is the filter clean? (Y/N)
Static Pressure (Ps) in supply plenum: "WG
(Measure at approximately 3 ft downstream of blower discharge)
Ps in return duct (downstream of filter, upstream of coil) "WG
SpacePak Motor: Amps (measured): Amps
Voltage (measured): Volts
Air Temperatures:
@ Return (indoor ambient): °FDB; °FWB
@ Condensing unit (outdoor ambient): °F
@ AHU (read 3 ft from fan discharge) °F
@ last supply outlet °F
Refrigeration-side Data:
Line sizes: Liquid Suction
Total equivalent length of lines: Ft; Vertical Rise: Ft.
@ Condensing Unit:
Liquid: psi; Temp: °F; Subcool: °F
Suction: psi; Temp: °F; Superheat: °F
@SpacePak:
Liquid: psi; Temp: °F; Subcool: °F
Suction: psi; Temp: °F; Superheat: °F
Approximate time running before taking readings: Hrs.
Did you adjust the TXV? (Y/N); (If yes, explain):
Refrigerant Charge (if weighed-in): lbs
R410a / R22 (circle one)
Installed options: (circle one)
sight glass filter/drier zone controls
Other:
Water Data:
(where applicable)
Line sizes: "; Length: FT
Water temperatures:
Suppy: °F; Return °F
Glycol?: (Y/N); % Solution:
NOTES:
Service / Troubleshooting FORM “1A”
REF. PART UNIT PART
NO.* DESCRIPTION SIZE NUMBER
27
FIGURE 4.1: MODEL ESP-G GENERAL ASSEMBLY
*Item locations within control box may vary.
1 Anti-Frost Control All Sizes 460RWG0378-01
Primary Drain Pan 2430 W06RWG0220-02
2 Primary Drain Pan 3642 W06RWG0220-03
Primary Drain Pan 4860 W06RWG0220-04
Coil Assembly R410A 2430 469RWG0379-12
3 Coil Assembly R410A 3642 469RWG0379-13
Coil Assembly R410A 4860 469RWG0379-14
Expansion Valve (TXV) R410A 2430 W28RWG0242-12
4 Expansion Valve (TXV) R410A 3642 W28RWG0242-13
Expansion Valve (TXV) R410A 4860 W28RWG0242-14
5 Transformer All Sizes W14RWG0061-01
Motor 2430 27-3236
6 Motor 3642 27-3237
Motor 4860 27-3238
Blower Wheel 2430 27-8032
7 Blower Wheel 3642 27-8032
Blower Wheel 4860 27-8033
8 Terminal Block (high volt) All Sizes W09RWG0422-01
9 Electrical Control Box Cover All Sizes 462RWG0529-01
10 Side Access Panel (coil side) All Sizes 462RWG0273-01
11 Primary Float Switch All Sizes 455RWG0543-01
12 Cable Connector (Ground) All Sizes W09RWG0313-01
13 Control Board All Sizes W11RWG0478-01
LIMITED WARRANTY
Central Air Conditioning Products
The “Manufacturer” warrants to the original owner at the original installation site that the Central Air
Conditioning Products (the “Product”) will be free from defects in material or workmanship for a period not to
exceed one (1) year from the startup or eighteen (18) months from date of shipment from the factory, whichever
occurs first. If upon examination by the Manufacturer the Product is shown to have a defect in material or
workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the
Product 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 written
instructions, or has been altered or modified in any way.
b) to any expenses, including labor or material, incurred during removal or reinstallation of the defective
Product 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 with
respect 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 OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND
EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE
IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE
WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR
ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL
OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH
MAY VARY BY EACH JURISDICTION.
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