United CoolAir VariCool EZ-Fit 15, VariCool EZ-Fit 35, VariCool EZ-Fit 25, VariCool EZ-Fit 30, VariCool EZ-Fit 40 Installation, Operation And Maintenance Manual

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VariCool
EZ-Fit Series
Installation, Operation and Maintenance Manual
Effective January 2018
Water-Cooled and Chilled Water
Variable Air Volume
Contents
VariCool EZ-Fit
Important Notice ������������������������������������������������������������������4
Use of Symbols �������������������������������������������������������������������4
General Information �������������������������������������������������������������5
Inspection of Equipment ������������������������������������������������5
Handling ������������������������������������������������������������������������5
Location �������������������������������������������������������������������������5
Application Data ������������������������������������������������������������5
Service Clearances �������������������������������������������������������������6
Condensate Drain����������������������������������������������������������������7
Physical Data������������������������������������������������������������������� 8-9
Mounting and Placement ���������������������������������������������������10
Suggested Assembly Sequence ����������������������������������������10
Mounting Options ��������������������������������������������������������������10
Evaporator Section ������������������������������������������������������������12
Gasket Material �����������������������������������������������������������������12
Compressor / Condenser Section �������������������������������������12
3D-Intelliclamps �����������������������������������������������������������������12
Refrigerant Connections ����������������������������������������������������16
Supply Air Blower Section �������������������������������������������������16
Duct Connections ��������������������������������������������������������������16
Water Piping ����������������������������������������������������������������������17
Water requirements �����������������������������������������������������������17
Transformer �����������������������������������������������������������������19
High Static Pressure Switch ����������������������������������������19
Inter-Module Control Power ����������������������������������������19
Evaporator Control Wiring �������������������������������������������19
Wall Display �����������������������������������������������������������������19
Static Pressure Transducer �����������������������������������������20
Supply Air Temperature Sensor �����������������������������������20
Return Air Temperature Sensor �����������������������������������20
Voltage Unbalance ������������������������������������������������������������20
Electric Heat ����������������������������������������������������������������������20
Maintenance Procedures���������������������������������������������������21
Filters ���������������������������������������������������������������������������������21
Blowers ������������������������������������������������������������������������������21
Lubrication �������������������������������������������������������������������������21
Belt Driven (DWDI) ������������������������������������������������������21
Frequency of Lubrication ���������������������������������������������21
Belt Tensioning ������������������������������������������������������������������22
Direct Drive Blowers ����������������������������������������������������������22
Drain Pan���������������������������������������������������������������������������23
Evaporator Coil ������������������������������������������������������������������23
Coil Cleaning ���������������������������������������������������������������23
Condenser Cleaning ����������������������������������������������������������23
Water Side Economizer Coil ����������������������������������������������23
Water Valves����������������������������������������������������������������������23
Refrigerant Systems ����������������������������������������������������������24
Operations Verication Check List�������������������������������������25
Troubleshooting Guide ������������������������������������������������������26
Limited Warranty ���������������������������������������������������������������29
Important Notice! ���������������������������������������������������������29
Exclusions �������������������������������������������������������������������29
To obtain warranty service �������������������������������������������29
Limited Warranty for Hermetic Compressors ��������������������30
Exclusions �������������������������������������������������������������������30
To obtain warranty service �������������������������������������������30
Limited Warranty Condensing Section ������������������������������31
EXCLUSIONS �������������������������������������������������������������31
To obtain warranty service �������������������������������������������31
Limited Warranty for Hermetic Compressors ��������������������32
EXCLUSIONS �������������������������������������������������������������32
To obtain warranty service �������������������������������������������32
Air-Cooled Unit �����������������������������������������������������������������33
Start-Up Procedures (R-410a Systems) ���������������������� 33-34
Optional Heating Start Up: ������������������������������������������34
Air-Cooled Unit �����������������������������������������������������������������35
Start-Up Procedures ����������������������������������������������������35
Cooling Mode ��������������������������������������������������������������36
Electrical ����������������������������������������������������������������������36
Heating Mode (Optional) ���������������������������������������������36
Water-Cooled Unit ������������������������������������������������������������37
Start-Up Procedures (R-410a Systems) ���������������������� 37-38
Water-Cooled Unit ������������������������������������������������������������39
Start-Up Procedures ����������������������������������������������������39
Cooling Mode ��������������������������������������������������������������40
Electrical ����������������������������������������������������������������������40
Heating Mode (Optional) ���������������������������������������������40
Subject to change without notice. 40.20-IM (0118)
3
VariCool EZ-Fit
Important Notice
This manual is the property of the owner.
Please be sure to leave it with the owner when you leave the job.
Use of Symbols
This publication includes warnings, cautions and information icons that point out safety related issues or conditions as well as other pertinent information relative to a safe installation, service or maintenance situation� The following icons should be interpreted as follows:
ELECTRICAL HAZARD
WARNING
CAUTION
INFORMATION
The electrical hazard icon indicates the presence of an electrical hazard which could result in electrical shock or death�
The warning icon indicates a potentially hazardous situation which could result in death or serious bodily injury if not avoided�
The caution icon indicates a potentially hazardous situation which may result in minor or moderate injury if not avoided�
The information icon indicates a situation that may result in equipment or property damage� The information provided alerts the reader to relevant facts and/or conditions�
Subject to change without notice. 40.20-IM (0118)
4
General Information
VariCool EZ-Fit
NOTE: This manual covers the standard unit congurations.
Since many units are built-to-order some of the information provided may not directly apply to this
specic unit.
Inspection of Equipment
Upon receiving of the unit, carefully inspect all sections for visible or concealed interior / exterior damage� If damage occurred during transit, contact the freight carrier immediately
and le a damage claim report.
Inspect the unit data plate to verify the model unit that was ordered is what has been received�
Some options / accessory items may have been shipped loose in one or more boxes� These may have been delivered to another location, or possibly within the unit� If shipped with
the unit there will be a sticker that identies where in the unit the shipped loose items are located. Conrm that all of
these options / accessory items are also available and that no damage has occurred�
Handling
To help facilitate handling, most units or modules are set on a wooden skid� Use caution when moving the unit or modules so that damage does not occur when moving each piece to
the nal installation location within the structure.
The units or modules can be moved by the use of a crane, fork lift, pallet jack or roller bars as appropriate� Under no circumstances should the unit or modules be “walked” on the corners of the skid or unit�
If a crane, cables or slings are used to move a unit or module, spreader bars must be used to protect each section’s cabinet structure�
INFORMATION
Unit should NOT be located in space subject to freezing temperatures�
Location
Before unit can be installed, a thorough study should be made of the structure� Attention must be given to:
A. Floor, ceiling or wall load limitations as appropriate
B. Required service clearances
C. Condensate removal, trapping and disposal
D. Location of wiring and safety devices
E. Ductwork sizing and connections are per industry
standards
F. Maintenance access
G. Mounting location is level in both horizontal planes
H. If appropriate, water piping location and connection
conguration
Application Data
Voltage 208 / 230 460 575
Variation 187 / 253 414 / 504 518 / 632
Cooling
(Air Entering Evaporator)
Water-Cooled
DB
(min./max.)
WB 57 / 72
GPM / Ton
(min./max.)
Leaving Water
(min./max.)
65 / 110
2.5 / 3.5
60 / 115
Subject to change without notice. 40.20-IM (0118)
Note: Not all combinations may be valid.
5
Service Clearances
VariCool EZ-Fit
36
24
24
TOP
Single DWDI Modules
TOP
36
24
24
24
36
24
TOP TOP
36
24
242424
Dual Modules Single DDP Modules
Notes:
(a) Service clearances apply to all air path congurations. (b) Service clearances apply to all size units� (c) Service clearances apply to both DWDI and DDP blower models in dual module conguration.
Subject to change without notice. 40.20-IM (0118)
6
Condensate Drain
Each EZ-Fit evaporator has a condensate drain connection in the base frame (Ref� Figure 1)� If the application contains dual modules two (2) drain traps are required�
Traps will need to be connected to the 1-1/4” NPT drain connection(s) (Ref� Figure 1)�
A condensate drain trap must be eld fabricated and
installed� The purpose of the trap is to neutralize the negative pressure created within the blower cabinet�
The negative pressure can vary from less than 1” up to 3”
column. The condensate trap must be of sufcient depth in water column to permit the condensate to ow from the drain pan. Failure to have a sufcient drain trap will cause the condensate to overow the drain pan or to cause the unit to shut down on the drain pan overow safety.
The “A” dimension (Ref� Figure 2) must equal or exceed the negative static pressure developed by the supply air blower� The “A” dimension will be unique for each unit application� The trap must be 2-1/2” deep to maintain a water seal under all operating conditions, especially during blower start-up�
It is highly recommended that the trap be primed with water prior to start-up�
Each trap must be piped to a suitable waste drain�
VariCool EZ-Fit
1�047
Condensate Drain
1-1/4" NPT
4�276
Figure 1 - Condensate Drain Location
Plugged Removable Cleanout
A
2�5
Min
3�5
Figure 2 - Condensate Trap Dimensions
Subject to change without notice. 40.20-IM (0118)
7
VariCool EZ-Fit
Physical Data
Model 12 15 20 25
Capacity (a) (MBH)
CFM 4800 6000 8000 9000 GPM 36.0 45.0 60.0 72.0 EER 15.1 14.4 14.8 14.1
Blower
Filter
Evaporator Coil
Condenser
Return Air Duct Size 51-3/8” H x 40” W 55” H x 50-1/2” W Supply Air Duct Size 16-1/4” H x 18-7/8” W 19” H x 22-3/16” W
Compressor
Refrigerant
Weight (b) (Net Operating)
Dimensions
(a) Capacity based on 80° F DB / 67° F WB with 85° F EFT (b) Basic unit only� Options will add weight for general purposes only actual charge may vary due to options and available heat
exchangers as ordered�
Total 165.8 202.0 260.2 300.9 Sensible 117.1 143.5 187.7 213.0
Type (QTY) DWDI Size (Dia.) 15 - 15 18 - 18 CFM Range 2200-5800 2600-6900 3500-9500 3500-9500 Type Pleated Throwaway Size (All 2” Thick.) 15 x 20 / 20 x 20 18 x 25 Qty 4 / 2 6 Efciency MERV 8 Type Interlaced Face Area (Sq. Ft.) 10.6 12.7 17.3 17.3 Rows 4 FPI 12 Type Co-Axial Working Pressure - Fluid 400 psig
Type Hermetic Scroll Qty 2 Type R-410a Lbs-Ozs 10.5 13 15 17 Evaporator 375 525 Condensing 800 1075 Blower (DWDI) 475 575 Blower (DDP) 500 650 Assembly w/ DWDI 1650 2175 Assembly w/ DDP 1675 2250 Evap. & Filter 54” W x 21-1/2” D x 56” H 64” W x 21-1/2” D x 59” H Comp. & Cond. 54” W x 31-1/2” D x 56” H 64” W x 34” D x 59” H Blower 54” W x 48” D x 32” H 64” W x 50-1/2” D x 34” H Assembly 54” W x 53” D x 88” H 64” W x 55-1/2” D x 93” H
Subject to change without notice. 40.20-IM (0118)
8
Physical Data continued
Model 30 35 40 45
Capacity (a) (MBH)
CFM 12000 14000 GPM 90.0 105.0 EER 14.0 14.0
Blower
Filter
Evaporator Coil
Condenser
Return Air Duct Size 69” H x 60” W 69” H x 64” W Supply Air Duct Size 24-7/8” H x 15-1/2” W 24-7/8” H x 19” W
Compressor
Refrigerant
Weight (b) (Net Operating)
Total 382.2 451.6 Sensible 283.5 330.7
Type (QTY) DDP (2) Size (Dia.) 16.5 18.2 CFM Range 4800-13000 5500 - 14900 Type Pleated Throwaway
Size (All 2” Thick.) 24 x 20 / 20 x 20
Qty 6 / 3 2 / 5 / 2 Efciency MERV 8 Type Interlaced Face Area (Sq. Ft.) 23.9 27.1 Rows 5 FPI 10 Type Co-Axial Working Pressure - Fluid 400 psig
Type Hermetic Scroll Qty 2 Type R-410a Lbs-Ozs 30 40 Evaporator 1000 1170 Condensing 1340 1570 Blower (DWDI) X X Blower (DDP) 800 (2) 1040 (2) Assembly w/ DWDI X X Assembly w/ DDP 3940 4820
Evap. & Filter
69” W x 27-1/2”
D x 71” H
20 x 20 / 20 x 24
/ 24 x 24
76” W x 29-1/2”
D x 71” H
VariCool EZ-Fit
Comp. & Cond. 69” W x 34” D x 71” H 76” W x 34” D x 71” H
Dimensions
Blower
Assembly
(a) Capacity based on 80° F DB / 67° F WB with 85° F EFT (b) Basic unit only� Options will add weight for general purposes only actual charge may vary due to options and available heat
exchangers as ordered�
Subject to change without notice. 40.20-IM (0118)
34-1/2” W x 56-1/2”
D x 34” H
69” W x 56-1/2”
D x 105” H
38” W x 58-1/2”
D x 34” H
76” W x 58-1/2”
D x 105” H
9
Mounting and Placement
VariCool EZ-Fit
Suggested Assembly Sequence
1. Set Evaporator section in place�
2. Set Compressor / Condensing section in place�
a. On Dual Module systems connect the water pipes�
3. Connect resealable refrigerant ttings.
4. Attach tie plates
5. Set Blower section in place�
6. Attach tie plates�
a. On Dual Module systems connect the electrical from
one module to the other�
NOTE: If space is limited in the mechanical room it may
be advantageous to suspend the blower section(s)
temporarily as the initial step.
Each module has three or more sections� If the system is comprised of dual modules, there will be left hand and right hand sections�
Each section will be labeled as to which system it is� These labels are typically something such as AC-1, AC-2 or AHU­1, AHU-2, etc� Make sure when mating up the sections that each section is correctly matched for the appropriate module�
Additionally, when a dual module system is being assembled there will also be an indication as to which sections are left hand (LH) or right hand (RH)� Left and Right hand is determined when viewing the unit from the control box side
(side opposite the lters).
Each section is also alphabetically labeled so that each section can be mated properly� Set the sections so that point:
A aligns to A
B aligns to B
C aligns to C
etc�
Please ensure that it is recognized that the ezt requires
support on the bottom middle of the unit� This means that
corner loading is insufcient for the task of placing an ez t unit. The ez-t requires support on the corners, the middle
of each section, and wherever sections come together� This observation is critically important, if these methods are not followed refrigeration pipe breakage will occur and UCA will refuse warranty of any kind of pipe breakage or leaks if an ez
t module is not supported by the means supplied herein this section. The UCA Recommended way is shown on gure 3B
notice where the middle beam supports the mid-section of the unit�
Figure 3A -Spring Isolation Base
Mounting Options
When installing any oor mounted unit, it is sometimes
desirable to include some form of vibration isolation� Please note that the unit frames have not been designed for corner point only loading with vibration isolation methods�
Vibration isolation can be achieved by use of wafe pads
or spring isolation. These are eld supplied and applied
accessory items� The selected choice of vibration isolation should be placed as appropriate in the sequence of placement of the unit sections�
Subject to change without notice. 40.20-IM (0118)
Figure 3B -Unit Positioned On Spring Isolation Base
10
VariCool EZ-Fit
Another equally recognized and recommended base support
of the ez t is shown on gure 3C which is channel steel
of an approved gauge to support the weight, simply placed underneath the unit in 4 locations per module or 7 locations
per dual module pairing. Place wafe pad type furnace pads
underneath the channel iron inside the C facing down for sound dampening� It is important that the channel does not touch the ground or sound dampening will not occur� It is also important that all the channels are level before placing the unit atop them� Please note the locations of the pads�
If height and other reasons prevent adequate space for
framing wafe pads alone may be used reference gure
3E� It is highly recommended that each pad be of identical height and that the pads are kept no smaller than 4”x 4”� You
will need at minimum 30 pads to support the ezt properly. Additional pads; more than the specied count can only help
the units support, the goal is to keep the middle of the unit from sagging, support under the compressors and water coils is key�
Figure 3E - Base Option 3 Bottom View
Figure 3C - Base Option 2 Bottom View
Figure 3D - Base Option 2 Unit View
Figure 3F - Base Option 3 Unit View
Subject to change without notice. 40.20-IM (0118)
11
VariCool EZ-Fit
Evaporator Section
Start by locating the evaporator section rst. Set each section
as needed, making sure that in dual module applications the evaporator sections are placed correctly as left hand and right hand�
Gasket Material
Gasket material has been factory supplied for eld
installation between each unit section� The gasket material must be installed to minimize air leakage and to help reduce transmission of noise�
Before applying any gasket material make sure the surface is clean and dry�
Gasket material, 3” wide, should be applied to those surfaces
identied as “3” in Figure 4 (evaporator and compressor /
condensing section)�
Gasket material, 2” wide, should be applied to those surfaces
identied as “2” in Figure 4 (evaporator and compressor /
condensing section)�
Blower
Section
Compressor / Condenser Section
Next, locate the compressor / condenser section(s)� Again, make sure the labels align properly for either the single or dual module applications�
On the refrigerant resealable ttings, apply a few drops of
refrigerant oil to the male coupling halves before starting the assembly (Ref� to Figure 6)�
3D-Intelliclamps
Each section of a single module is furnished with 3D-Intelliclamps to facilitate connection to the adjacent section� These have been installed at the factory during production and consist of two interlocking halves that mate and are then bolted together� Once tightened, they ensure perfect alignment of the mating section surfaces�
Once adjacent sections have been put into place, use the included hardware to pull sections together until the curved surfaces of the 3D-Intelliclamps are completely mated�
Evaporator Section
3
Figure 4 - Gasket Material
Subject to change without notice. 40.20-IM (0118)
2
Condensing Section
3D-Intelliclamp
12
VariCool EZ-Fit
DETAIL "A"
TYP 8 PLCS
MOUNTING SCREWS
MOTOR
IN OUT
LEFT
DETAIL "A"
TIGHTENING SCREW
ELECT
FRONT
VFD
Subject to change without notice. 40.20-IM (0118)
RETURN
AIR
REARRIGHT
Figure 5A 20 - 70 Ton Single
13
TY
VariCool EZ-Fit
DETAIL "A"
P 16 PLCS
LEFT
MOUNTING SCREWS
MOTOR
IN OUT
DETAIL "A"
ELECT
TIGHTENING SCRE W
VFD
VFD
FRONT
ELECT
MOTOR
Subject to change without notice. 40.20-IM (0118)
NRUTERNRUTER
RIARIA
RAER THGIR
Figure 5B 20 - 70 Ton Dual
14
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