York K3EU180A50 User Manual

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Page 1

CAUTION

THE ENCLOSED INSTAL L ATI ON INSTRUCT I ONS AND ANY APPL I CABL E

LOCAL, STAT E , AND NATIONAL CODES INCLUDING, BUT NOT LIMI T E D

TO, BUILDING, ELECTRICAL, AND MECHANICAL CODES.

THIS PRODUCT MUST B E INSTALLED IN STRICT COMPLIANCE WITH

WARNING

OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAM AGE.

I NCORRECT INSTALLATI ON MAY CREATE A CONDITI ON WHERE THE

SUNLINE™ SPLIT-SYSTEM

EVAPORATOR BLOWER

(AIR COOLED)

INSTALLATION INSTRUCTION

GENERAL

This completely assembled blower unit is manufactured under ISO 9002 Quality System Certification and includes a wellinsulated cabinet, a DX cooling coil with copper tubes and aluminum fins, an expansion valve, a distributor, throwaway filters, a centrifugal blower, a blower motor, a blower motor contactor, an adjustable belt drive and a small holding charge of Refrigerant-22.

The unit is shipped in the vertical position with a vertical air discharge.Theblowersection canbe repositionedas shownin Figure1 for horizontal applications.

REFERENCE

This instruction covers the installation of the evaporator blower unit. For information on the installation and operation of the matching condensing unit refer to Form 035-17263-000.

Additional information for the accessories on this equipment is available in the following instructions:

Supersedes: 550.39-N5YI (894) 035-12124-000 Rev. A(0501)

MODEL K3EU180A50

(WORLD 50 HZ)

INSPECTION

Assoonas aunit isreceived, itshouldbe inspectedfor possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier's delivery receipt. A separate request for inspection by the carrier's agent should be made in writing. See Local Distributor for additional information.

Product Category

K = Split-System Evaporator Blower

Product Generation

1,2,3 = Design Level

Product Identifier

EU = Evaporator Blower Unit

NominalCooling Capacity

180 = 180Mbh (52.7kW)

NOMENCLATURE

180

•

Electric Heater - 550.13-N10.1V

•

Supply Air Plenum - 550.13-N10.2V

•

Return Air Grille - 550.13-N10.3V

•

Base - 550.13-N10.4V

•

Hot Water & Steam Coil - 550.13-N10.7V

•

Suspension Mounting - 550.13-N7.1

Renewal Parts:

•

Refer to Parts Manual for complete listing of replacement parts on this equipment.

All forms may be ordered from:

Standard Register 2101 West Tecumseh Road

Installershouldpay particularattention tothewords: NOTE, CAU TIONand WARNING.Notes

age.Warnings

Norman, OK 73069

areintended toclarify ormake theinstallation easier. Cautionsare givento preventequipment dam

aregivento alertinstallerthat personalinjury and/or equipmentdamage may resultif installationprocedureis not

Refrigerant Line Connections A = Cooling Only

Voltage Code 50 = 380/415-3-50

Page 2

035-12124-000 Rev. A(0501)I

INSTALLATION

LIMITATIONS

Theseunits mustbeinstalled inaccordancewithapplicablena tional, local and municipal safety codes.

If components are to be added to a unit to meet local codes, theyare tobe installedatthedealer'sand/or thecustomer's ex pense. Refer to Table 2 for Unit Application Data.

LOCATION

This blowerunit is notdesigned for outdoorinstallation. Itmust be locatedwithin the buildingstructure, either insideor outside the conditioned space.

The unit should be located as close to the condensing unit as practical and positioned to minimize bends in the refrigerant piping.

Unitsbeing installedverticallyorhorizontallycan besetdirectly on a floor or platform, or they can be supported by metal or wooden beams.

Units being installed horizontally can also be suspended from above. Refer to the suspension accessory instruction installa tion procedures.

CLEARANCES

The clearanceslisted on theunit dimension drawing(Figure 7) are required for the proper service and operation of the unit.

RIGGING AND HANDLING

Becareful whenmovingtheunit.Do notremove anypackaging until the unit is near its final location.

The packaging consists of a bottom wooden skid that can be lifted witha fork truck from anydirection, a clear heavy milbag that coversthe entire unit,and strapping thatsecures the clear bag to the bottom of the skid.

Table 1 - PHYSICAL DATA

Evaporator Coil

Centrifugal

Blower

Filters (6 Req'd)

Operating Charge ( Refrigerant 22) (Lbs/Kg) 5.5/2.5

Weight (Lbs/Kg)

Accessory Weights(Lbs/Kg)

Refer to data in Table 7 for complete motor specifications.

Filters are throwaway type. Twoinch (50mm)filters may be used, if required by removing the 1" (25mm) filter retaining angles provided in the filter rack.

Rows Deep 4 Rows High 26 Finned Length (in./mm) 54.5/1384 Fin/Inch 13 Tube O.D. (in./mm) 3/8/9.6

.2/m2

Face Area (Ft

Wheel Dia. x Width

Size

Face Area (Ft.

Shipping 480/218 Operating 440/200

Electric Heaters

Supply Air Plenum 144/65 Base 65/29 Return Air Grille 19/9 Horizontal Suspension 68/31 Steam Coil 149/68 Hot Water Coil 135/61

) 12.4/1.15

inches 18 x 18

mm 457 x 457

inches 20 x 20 x1

2/m2

) 16.7/1.5

10 kW 63/28.5 16 kW 66/29.9 26 kW 71/32.2 36 kW 74/33.5

508 x 508

x 25

These units can be rigged with slings under the bottom skid.

CAUTION: Spreader bars should be used to prevent slings

from crushing the unit panels and frame.

Before riggingany unit, determineitsweight from Table1. Bef

ore rigging a unit for horizontal installation, make sure that its weight will be distributed equally.

TABLE 2 - UNIT APPLICATION DATA

Power Supply

380/415-3-50 342 457 4800/2.26 7200/3.40 68/57 (20/14) 86/72 (30/22) - 77 (25)

*Utilization Range “A” in accordance with ARI Standard 110.

2 Unitary Products Group

Voltage

Variation*

Min. Max. Min. Max. Min. Max. Min. Max.

Supply Air Range

CFM/m

Entering Air Temperature, °F(°C)

Cooling-db/wb Heating-db

Page 3

FIG 1 - VERTICAL AND HORIZONTALAPPLICATION

035-12124-000 Rev. A(0501)

VERTICAL/HORIZONTAL INSTALLATION

Theunitis shippedfor verticalinstallation witha verticalairdis chargeasshown inFigure 1, butmay beconvertedto otherar rangements per the following instructions.

1.Remove the panels from the blower section.

2.Remove the four Phillips machine bolts that hold the coil and blower sections together. A bolt is located near each corner.

3.Move the blower section to the proper location.

4.Attach the blower section to the coil section with the machine bolts removed in Step 2.

5.Beforereplacing thepanel, seeDuct Connectionand Drain Connection.

6.Replace the panels.

DUCT CONNECTIONS

All ducts should be designed and installed in accordance with applicable national and/or local codes.

Ducts should be sized no smaller than the duct flanges on the unit or the accessory electric heater(ifused).Refer to the unit dimensions(Figure7) andthe heaterdetail (Figure2) forthese sizes.

The field installed air plenum and return air grille accessories shouldbeused inplace of ductworkonly whenafree blow/free return application is practical.

(25)

(489)

(565)

FIG. 2 - ELECTRIC HEATER ACCESSORY

REFRIGERANT MAINS

Many service problems can be avoided by taking adequate pre

cautionsto providean internallycleananddrysystem,andbyus ing procedures and materials that conform with established standards.

Hard drawncoppertubing should be usedwhere no appreciable amount of bending around pipes or other obstructions in necessary.Use long radius ells whereverpossible.If soft copper is used, care should be taken to avoid sharp bends which may cause a restriction.

Pack fiberglass insulation and asealing material such asPermagum aroundrefrigerant lines wherethey penetrate awallto reduce vibration and to retain some flexibility.

Support all refrigerant lines at minimumintervalswithsuitable hangers, brackets or clamps.

Braze all copper to copper joints witH Sil-Fos 5 or equivalent brazing material. Do not use soft solder.

Never braze or solder liquid and suction lines together. The complete suction line should be insulated with no less the (12mm) ARMAFLEX or equivalent.

If it is desirable to tape or wire the liquid and suction lines to gether for support purposes, they must be completely insu lated from each other.

INSTALLING REFRIGERANTMAINS The units are evacuated and dehydrated at the factory and

shipped with a holding charge of Refrigerant-22. The suction and liquid connections are sealed with copper disks.

WARNING: Provisions for recovering refrigerant releases

If the unit has already lost itsholdingcharge, it should be leak tested and the necessary repairs should be made. If the unit has maintaineditsholding charge, you can assume that ithas no leaks and proceed with the installation.

Make sure the refrigerant in the lines has been recovered, then drill a small hole through the discs to prevent any inter nal pressure from blowing them off and to allow the flow of dry nitrogen through the connections when unbrazing the closures.

must be available during all phases of installation, leak testing and charging. Do NOT release refrig erantinto theatmosphere. ASchradervalveispro vided on the coil header for recovering refrigerant holding charge.

Unitary Products Group 3

Page 4

035-12124-000 Rev. A(0501)

NOTE: To minimize the possibility of system failure due to dirt

andmoisture, afilter-driermustbeinstalledineachliq uid line as close to the evaporator as possible. Filterdriers are not supplied with the evaporator blowers. They aresuppliedwith the matching condensing sec tions.

The temperature required to make or break a brazed joint is sufficiently high to cause oxidation of the copper unless an inert atmosphere is provide.

CAUTION:Dry nitrogenshouldflow throughabrazedjointatall

times whenheatis being applied anduntilthe joint has cooled.

The liquid, suction and drain connections inside the unit must be piped to the outside. Refer to Unit Dimensions for loca

tions of the access openings in the unit panel. Protective grommets are supplied by the factory for field

placement into these access openings. The blower units are shipped with the coil section side pan

els suitable for right hand piping connections when viewed from the return air side of the unit.

The refrigerant piping and the condensate drain connection may be routed through either side of the unit.

If left hand piping is required, the two panels on the right side of the coil section can be interchanged with the single panel on the left hand side of the coil section.

When left hand piping connections are installed, the suction line must be insulated to prevent moisture from condensing and being carried into the blower section.

EXPANSION VALVE BULB The expansion valve bulb must be fastened in a 4 o'clock po-

sition to the suction line outside the cabinet after the piping connections have been made. Use the clamps supplied with the valve.

DRAIN CONNECTION

The drain line MUST be trapped because the coil is located on the negative side of the supply air blower. It must also be protected from freezing temperatures.

" (22.2mm) OD stub connection is provided within the

cabinet on both ends of the condensate drain pan for either

left hand or right hand piping connections. Refer to Figure 3 for recommended drain piping.

The drain line is usually located on the same end of the coil section as the refrigerant connections. The line should be in

sulated where moisture drippage will be objectionable or cause damage to the area. Seal the unused drain connec tion with a suitable mastic.

The 3" (76mm) dimension must equal or exceed the nega tive static pressure developed by the supply air blower. If it does not, condensate will not drain properly and may over flow the drain pan. The trap must be at least 2" (50mm) deep to maintain a water seal under all operating conditions, espe cially during blower start-up.

SUPPLY AIR BLOWER ADJUSTMENT

The RPM of the supply air blower will depend on the re quired airflow, the unit accessories and the static resistances of both the supply and the return air duct systems. With this information, the RPM for the supply air blower can be deter mined from the blower performance in Table 5

Knowing the required blower RPM and the blower motor HP, the setting (turns open) for the supply air motor pulley can be determined from Table 3..

TABLE 3 - SUPPLY AIR BLOWER MOTOR PULLEY ADJUSTMENT

TURNS OPEN*

5 615 4 652 3 689 2 726 1 763 0 800

* Pulleys can be adjusted in half-turn increments.

Each motor pulley has:

1.Athreaded barrel with two flats (or notched recesses) 180 degrees apart.

2.Amovable flange with one set screw.

After the movable flange has been rotated to the proper number of “turns open”, the set screw should be tightened against the flat on the barrel to lock the movable flange in place. If the pulley includes a locking collar, the locking collar must be loosened to adjust the setting of the movable flange.

BLOWER DRIVE RANGE (RPM)

615-800

Note the following:

1.The supply airflow must be within the limitations shown in Table 2.

(76)

(50)

2.All pulleys can be adjusted in half-turn increments.

3.Thetensionon the belt should be adjusted for a deflection

" (5mm)per foot (305mm) ofbelt span withanapplied

force of approximately 3 lbs (1.4kg). This adjustment is madebymoving theblower motor mountingplate. Referto Figure 4. Turningthe adjustment bolt (B) moves the motor mounting plate up or down. Note - Never loosen the two nuts (C). Four hex nuts (A) have to be loosed to move the mounting plate and retightened after the mounting plate

FIG 3 - RECOMMENDED DRAIN PIPING

4 Unitary Products Group

has been moved to the proper position.

Page 5

4.All pulleys are factory aligned.

5.All supply air motor pulleys are factory set at two “turns open.”

After the supplyair blower motor is operating, adjusttheresis tances in both the supply and the return duct systems to bal ancetheair distributionthroughout theconditioned space.The job specifications may require that this balancing be done by

035-12124-000 Rev. A(0501)I

operation, check the belt and pulleys for tightness and align ment.

WARNING:Failure toproperlyadjust thetotal systemairquan

Afterreadingshave beenobtained, removethetubes andseal up the drilled holes in the side panel with

tity can result in extensive blower damage.

" (8mm) dia. dot

(559)

(8)

(457

FIG 4 - TYPICAL MOTOR MOUNTING ASSEMBLY

someone other than the equipment installer. Tocheck thesupplyair airflowafter thethe initialbalancing has

been completed:

1.Drilltwo holes Figure 5.

2.Insert at least 8" (200mm) of each of these holes for sufficient penetration into the air flow on both sides of the evaporator coil.

NOTE: The tubes must be inserted and held in a position per

pendicular to the airflowso that velocity pressure will not affect the static pressure reading.

3.Usingan inclinedmanometer,determine thepressuredrop across a dry evaporator coil. Since the moisture on an evaporator coil may vary greatly, measuring the pressure dropacrossa wetcoilunder fieldconditionswould beinac curate. To assure a dry coil, the refrigerant system should be de-energized while the test is being run.

" (8mm)dia.in the side panelas shown in

" (6.3mm) O.D. tubing into

(254)

(8)

FIG 5 - HOLE LOCATIONS

TO DETERMINE PRESSURE DROP READINGS ACROSS THE DRY EVAPORATOR

plugs(P/N 029-13880)availablethrough normalpartsordering procedure.

NOTE; SHUT DOWN THE REFRIGERANT SYSTEM BEF-

ORE TAKING ANYTEST MEASUREMENTS TOASSURE A DRYEVAPORATOR COIL

4.Knowingthe pressuredrop across a drycoil, theactual air

flow through the unit can be determined from the curve in Figure 6.

If the airflow is above or below the specified valve, the supply air motor pulley may have to be readjusted. After one hour of

FIG 6 - PRESSURE DROP VS SUPPLY AIRFLOW

TABLE 4 - ELECTRICAL DATA

Blower Motor

HP/kW

3 / 2.2 380/415-3-50 5.2 37.0 10 400 (122)

* Dual element, time delay fuses.

** Based on three 60° C, 14 AWG, insulated copper conductors in steel conduit and a 3% voltage drop.

Unitary Products Group 5

Power Supply FLA LRA

Maximum

Fuse Size* Amps

Maximum

Wire Length* * Ft.(m)

Page 6

035-12124-000 Rev. A(0501)I

TABLE 5 - BLOWER PERFORMANCE

ESP

(Pa)

- (CFM)

OUTPUT

(BHP)

OUTPUT

(kW)

INPUT

(KW)

INPUT

(kW)

ESP

(IWG)

ESP

(Pa)

AIRFLOW

OUTPUT

(BHP)

AIRFLOW

OUTPUT

(kW)

INPUT

(kW)

INPUT

(kW)

ESP

(IWG)

ESP

(Pa)

OUTPUT

(BHP)

OUTPUT

(kW)

INPUT

(kW)

INPUT

(kW)

ESP

(IWG)

ESP

(Pa)

OUTPUT

(BHP)

OUTPUT

(kW)

INPUT

(kW

INPUT

(kW)

SUPPLY AIR BLOWER PERFORMANCE

BLOWER

SPEED

RPM

ESP

(IWG)

OUTPUT

(BHP)

INPUT

(kW)

(IWG)

4800 CFM 5400 CFM 6000 CFM 6600 CFM 7200 CFM 600 0.46 1.44 1.34 0.30 1.68 1.56 0.11 1.96 1.80 - - - - - 625 0.55 1.54 1.43 0.40 1.79 1.64 0.22 2.08 1.90 0.01 2.41 2.20 - - 700 0.84 1.83 1.68 0.70 2.12 1.94 0.54 2.43 2.22 0.36 2.77 2.54 0.12 3.12 2.82 800 1.26 2.38 2.17 1.15 2.70 2.47 1.00 3.03 2.74 0.83 3.37 3.05 0.62 3.75 900 1.70 2.95 2.68 1.63 3.30 2.99 1.52 3.67 - - - - - - -

SUPPLYAIR BLOWER PERFORMANCE1- (m3/s)

BLOWER

SPEED

RPM

ESP

(Pa)

OUTPUT

2.26 m

INPUT

(kW)

/s 2.55 m3/s 2.83 m3/s 3.11 m3/s 3.40 m3/s 600 114 1.07 1.34 74 1.25 1.56 27 1.46 1.80 - - - - - 625 136 1.15 1.43 99 1.33 1.64 55 1.55 1.90 3 1.08 2.20 - - 700 208 1.36 1.68 174 1.58 1.94 134 1.81 2.22 89 2.06 2.54 30 2.32 2.82 800 312 1.77 2.17 285 2.01 2.47 248 2.26 2.74 206 2.51 3.05 154 2.79 900 422 2.20 2.68 404 2.46 2.99 311 2.73 - - - - - - -

Unit resistance is based on a wet evaporator coil and clean filters.

Availablestatic pressure inIWG (Pa) toovercome the resistanceof the ductsystem and anyaccessories added tothe unit. Referto Table6 for theresistanceof these

accessories and to Table7 foradditional motorand drive data

NOTE: Motors can be selected to operate into the service factor because they are located in the moving air stream, upstream of any heating device.

LEGEND:

RPM range for standard factory-mounted drive components.

TABLE 6 - ACCESSORYSTATIC RESISTANCE (IWG)

ACCESSORY

BLOWER CFM/m

10kW 0.04 / 10 0.05 / 12 0.06 / 15 0.08 / 20 0.10 / 25

Electric

Heat

16kW 0.07 / 18 0.09 / 21 0.11 / 27 0.14 / 35 0.17 / 42 26kW 0.13 / 32 0.16 / 40 0.20 / 50 0.24 / 60 0.29 / 72

36kW 0.20 / 50 0.24 / 60 0.29 / 72 0.35 / 87 0.42 / 106 Supply Air Plenum 0.03 / 8 0.04 / 10 0.05 / 12 0.06 / 15 0.07 / 18 Return Air Grille 0.04 / 10 0.05 / 12 0.06 / 15 0.07 / 18 0.08 / 20 Hot Water Coil 0.18 / 45 0.22 / 55 0.26 / 64 0.30 / 74 0.34 / 84 Steam Coil 0.15 / 37 0.18 / 45 0.22 / 55 0.26 / 64 0.30 / 74

* Add these pressures to the ESP values in the respective blower performance table.

EXTERNAL STATIC PRESSURE DROPRESISTANCE

4800 /

2.26

5400 /

2.55

Exceeds the output limitation of the standard factory-mounted blower motor.

IWG/pA

6000 /

2.83

6600 /

3.11

7200 /

3.40

6 Unitary Products Group

Page 7

UNIT

035-12124-000 Rev. A(0501)

FIG 7 - UNIT DIMENSIONS AND CLEARANCES

ACCESSORIES

•ELECTRIC HEATER Add 15" (381mm) to Unit Height when using 10, 16, 26 or 36kW Heater

•SUPPLYAIR PLENUM Add 27" (686mm) to Unit Height when used

•BASE Add 24" (610mm) to Unit Height when used

MINIMUM CLEARANCES (in./mm) Side with RETURN AIR opening - 24 / 610

Side with SUPPLYAIR opening - 24 / 610 Side with PIPING CONNECTIONS - 61 / 1549 Side opposite PIPING CONNECTIONS - 26 / 660 Bottom -

NOTES:

Overall dimension of the unit will vary if an electric heater, a supply air plenum or a base is used.

This dimension is required for removal of the DX coil. Only 26" (660mm) is required for normal serv

icing.

If the DX coil has to be removed, this dimension is required to loosen screws that secure the coil to the unit frame. This dimension will also be required for blower motor access if the piping connections are made on the opposite side of the unit.

Allow enough clearance to trap the condensate drain line.

All dimensions are in millimeters and inches. They are subject to change without notice. Certified dimensions will be provided upon request.

Unitary Products Group 7

Page 8

TABLE 7 - BLOWER MOTOR AND DRIVE DATA

Motor

(HP/kW)

3 / 2.2 615/800

Blower Range

(RPM)

Adjustable Motor Pulley Fixed Blower Pulley Belt

Pitch Dia

(In./mm)

3.4 - 4.4 / 86

- 112

Bore

(In./mm)

/ 22.2

POWER AND CONTROL WIRING

Install electrical wiring in accordance with appli cable national, local and municipal codes. The unit should be grounded in accordance with these codes.

Route the power wires into the unit through one

of the with the supply air opening and connect them to the terminals on blower motor contactor 10M. Route the control wires into the unit through the other them to the terminals on block 4TB. Refer to the unit drawing in Figure 7 for the locations of these knockouts.

If the unit includes an electric heat accessory, route the power wires into heater control box instead of the unit. Refer to the electric heat instructions for additional installation information.

" (22.2mm) dia.knockouts in the panel

" (22.2mm) dia.knockout and connect

Pitch Dia.

(In./mm)

8.0 / 203 1 / 25 A54 55.3 / 1405

Bore

(In./mm)

Designation

TERMINALS ON 1-STAGE COOLING THERMOSTAT 2TH0870124

Pitch Lg. (In./mm)

MOTOR SPECIFICATIONS

•1450 RPM

•380/415-3-50

•Solid base

•56 Frame

•Inherently protected

•Permanently lubricated ball bearings

TERMINALSONBLOCK 3TB OF THE BLOWER UNIT

Refer to Table 4 to size the disconnect switch, the power wiring and the fuses. Refer to Figure 8 for typical field wiring.

FIG 8 - TYPICALFIELD WIRING (Cooling only)

NOTE:Threephase motorrotation maybeincor-

rect when the unitisfirststarted up. Re

verse phase (leads L1 and L2) at contactor to obtain the correct rotation.

MAINTENANCE

FILTERS— Thefiltersmustbereplaced asoftenasnecessary

to assure good air flow and filtering action. EVAPORATOR COIL—Donotallowdirt toaccumulate onthe

evaporatorcoil orother partsofthe evaporatoraircircuit.Clean as often as necessary to assure good system performance. Use a brush, vacuum cleaner attachment or other suitable means.

Subject to change without notice. Printed in U.S.A Copyright  by York International Corporation

LUBRICATION — The bearings for the blower shaft and the blower motors are permanently lubricated and should not re quire additional lubricant.

DRAIN PAN — The drain pan should be inspected regularly to assure proper drainage.

BELTS — Maintain belt tension to extend belt life. Replace when signs of failure begin to appear.

035-12124-000 Rev. A(0501) Supersedes: 550.39-N5YI (894)

Unitary

Products Group

5005 York Drive

Norman

73069