MODEL ESP-J & ESP-JV INSTALLATION, OPERATION & MAINTENANCE MANUAL - Mestek

FIGURE 1.4: ESP-3642/4860J INSTALLATIONSFIGURE 1.5: TERMINATOR IN SOFFIT AREAUNIT NO. 1FAN COIL UNITNO MORE THAN60% OF CAPACITYON ONE SIDEMINIMUM 18"ROOMTERMINATORFIGURE 1.6: TERMINATOR IN CLOSET TOP AREAUNIT NO. 2FAN COIL UNITMINIMUM 18"30% MAX. OF CAPACITYROOMTERMINATORThe larger system capacities (ESP-3642/4860J) areaffected more by higher system static pressure than thesmaller systems. Installation of the plenum tee closerthan the minimum indicated in Figure 1.4 will reduceperformance of the system. No supply runs should beinstalled between unit outlet and this tee. Staticreadings on system should be taken before tee.SUPPLYTUBINGTerminators should always be out of normal trafficpatterns to prevent discharge air from blowing directly onoccupants. And they should not be located directly aboveshelves or large pieces of furniture. Outside wall or cornerlocations are recommended if the room has more thanone outside wall. Locating terminators away from interiordoors prevents short cycling of air to the return air box.Supply TubingIn the case of two-story or split-level applications, supplytubing may run from one story to another. It is smallenough to go in stud spaces, but this is often difficult inolder homes because of hidden obstructions in studspaces. It is more common to run the supply tubing fromthe attic down through second story closets to the firststory terminators.SHIPMENT OF UNITEach fan coil unit is shipped in a single carton. Packed withthe unit, there are vibration isolation pads, a condensatetrap assembly and a factory installed primary float switch.Each unit comes from the factory charged with nitrogen.When the unit is unsealed, a slight “pop” or “hissing”noise should be heard. This guarentees that the unit isproperly sealed.Supply tubing runs in the corners of the second storyrooms can be boxed in and are hardly noticeable sinceoverall diameter is only 3-1/4".Room TerminatorsNOTICE: For high altitude systems use the followingchart as a guideline for number of outlets.Terminators should be located primarily in the ceiling orfloor for vertical discharge or high on a wall for horizontaldischarge. Installation of horizontally discharged terminatorsis assisted with the SpacePak 90 wall elbow (see page 19).Two excellent spots for horizontal discharge are in the soffitarea above kitchen cabinets (see Figure 1.5) and in the topportion of closets (see Figure 1.6).ALTITUDE5000 - 6500'6500' and above6MINIMUM NO. OFOUTLETS PER TON89

SECTION 2: SYSTEM INSTALLATIONNOTICE: Before proceeding with the installation, werecommend reading through this section of themanual for an overall understanding of the airconditioning fan coil unit and air distribution systemcomponent installation procedures.When selecting a location, consider the location of theunit in relation to the return air box or filter box as shownin Figure 2.5. The return air duct should have at least one90 bend to avoid unnecessary sound feedback to theliving space from the fan coil unit.Step 1: Locating the UnitWhen selecting a location, consider the layout of theplenum duct, supply tubing, refrigerant lines and condensate drain line.The fan coil unit may be installed in an unconditionedspace (as long as it is protected from the weather) suchas an attic, garage or crawlspace, or a conditioned spacesuch as a basement, closet or utility room (see dimensions in Figures 2.2, 2.3 and 2.4).When installing the unit above a finished ceiling or livingspace, install a secondary drain pan. Always follow localcode requirements.FIGURE 2.1: MODEL ESP-J SPECIFICATIONSConnectionsSystemcapacity(Nom. Tons)ModelSuctionElectricalLiquidCharacteristics* Line (O.D.) Line (O.D.)Cond.Drain(FPT)ReturnInlet(Dia.)ESP-2430J-V2 - 3 - "24"RecommendedCondensing UnitNominalMinCapacitySEER(MBH)24 to 3013 36 to 4248 to 6013 13 *Unit includes optional conversion kit to J-VSystemcapacity(Nom. Tons)Std. CFM@ 1.2"W.C.Wheel Dia.andWidth2 - 2-1/23 - 3-1/24-5440, 550660, 850880, 115010" x 6"10" x 6"10" x 6"MotorHP115V/230VF.L.Amps*No. ofRowsDeep3/43/43/45.6/2.87.6/410.6/5.4666*Unit includes optional conversion kit to 115V.FIGURE 2.2: UNIT DIMENSIONS AND CLEARANCES V105123144135170210

FIGURE 2.3: VERTICAL UNIT DIMENSIONS AND CLEARANCES (Inches)FIGURE 2.4: CONNECTION LOCATIONS AND ASSEMBLED PLENUM ADAPTOR DIMENSIONSFIGURE 2.5: TYPICAL UNIT INSTALLATIONCLAMP BANDFLEXIBLE RETURNDUCT (90 BEND)SPACEPAK FANCOIL UNITCLAMP BAND48" MIN.SUPPLY AIR OUTLETRETURN AIR BOXWITH GRILL & FILTERPLATFORM (FIELD ERECTEDAS SHOWN IN STEP 4)8

FIGURE 2.6: HORIZONTAL AIR FLOW UNIT INSTALLATIONSUPPORTRETURN AIR BOX90 14 Ft. MAXIMUM FLEXIBLERETURN DUCT2 Ft.MAX.SUPPORTFAN COIL UNITSUPPLY AIR90 PLATFORM (FIELD ERECTEDAS SHOWN IN STEP 4)FIGURE 2.7: TYPICAL CLOSET/UTILITY ROOM INSTALLATIONFIGURE 2.8: TYPICAL CLOSET INSTALLATION9

Step 2: Cutting Return Air OpeningSelect exact location for return air box. Avoid installingbox in dining room, living room, kitchen, etc., unlessreturn air duct can be installed with at least two 90 bends(accomplished by splicing two return air ducts together.)FIGURE 2.10For attic installations to raise fan coil unit up throughopening, cut return air opening 14-1/2" wide by the "A"dimension (Figure 2.9) of appropriate unit size. Theseopenings will accomodate the return air box withsufficient frame lip to cover the opening (see Figure 2.9).NOTICE: The return air adapter may need to be removedfrom the unit to fit through the opening cut-out.If joists are on 16" centers, the 14-1/2" width of the returnair box should fit between successive joists. Where joistsrun in the opposite direction, or to properly center thereturn, it may be necessary to cut joists and install headers.For all wall return applications, cut the return air openingto accomodate the return air box according to the samedimensions. Remember, location of opening must allowfor a 90 bend in the return air duct.Check the opening for proper fit of the return air box. Donot install the return air box until the installation of theentire SpacePak system is completed, if you want to fitmaterials up through this hole.FIGURE 2.11: PLENUM ADAPTOR ASSEMBLY#8 X 3/4MOUNTING SCREWS(10 SUPPLIED)10 INCH SQUARE SUPPLY AIRPLENUM ADAPTOR ASSEMBLY KITPART NO. AC-PAJSQStep 3: Attaching Supply AirPlenum AdaptorNOTICE: If unit is to be located in the attic andinstalled through ceiling joists, attach supply plenumadaptor in attic.A. HORIZONTAL DISCHARGE:Refer to Figure 2.11 and duct installation instructions supplied with fan coil unit.NOTICE: Allow space on sides for servicing.ESP-2436 (V) SHOWNFIGURE 2.9: RETURN AIR BOX FRAME DIMENSIONSSPL-WG0986 B1143210 INCH SQUARE SUPPLY AIR PLENUM ADAPTORANOTE RELATIVE POSITION OF PLENUMADAPTOR TO SUPPLY AIR OPENING37610 11625614-5/16"Measure return air box dimension "A" to determinelength of opening. Height 14-5/16"DWG004510 116256ALL DIMENSIONS ARE IN INCHES [mm]10SPL-WG0986 B

Step 4: Setting the UnitConstruct a platform for the fan coil unit, as shown inFigure 2.13. The platform can be constructed of 2 x 4 x 4(minimum), 2 x 6, 2 x 8 and 2 x 10 lumber, as necessaryto achieve proper pitch of 1/4" per foot for the condensatedrain line. Figure 2.12 shows the approximate normalallowable run of condensate piping as a function of theframing lumber used for platform construction. Theplatform covering should be 1/2" plywood minimum.For locations where the fan coil unit will be suspended,suspend platform from overhead by 1/4" threaded rods.NOTICE: Allow 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 ellipticalopening facing in the direction of the return air box. DONOT let the supply air plenum adaptor support theweight of the unit.Attach vibration isolation pads (supplied inside fan coilunit) to platform covering as shown in Figure 2.13.Do not secure the unit to the platform, as the weight ofthe unit will hold it in position.Secure the platform to the joist or floor, depending onlocation selected for the fan coil unit. Make sure platformis level.FIGURE 2.12: CONDENSATE PIPING RUNSLUMBER SIZE2X42X62X82 X 10MAXIMUMHORIZONTAL8'16'24'32'FIGURE 2.13: MOUNTING PLATFORMS SHOWN WITH VIBRATION ISOLATION STRIPS25"30"1 STRIP 4" x 15" x 1" THICKPOLYURETHANE FOAMWFLOAIR1 STRIP 4" x 9" x 1" THICKPOLYURETHANE FOAM4 STRIPS 4" x 30" x 1" THICKPOLYURETHANE FOAMFOR MODEL ESP-2430J30"34"1 STRIP 4" x 15" x 1" THICKPOLYURETHANE FOAMWFLOAIR1 STRIP 4" x 14" x 1" THICKPOLYURETHANE FOAM5 STRIPS 4" x 30" x 1" THICKPOLYURETHANE FOAMFOR MODEL ESP-3642J30"44"1 STRIP 4" x 15" x 1" THICKPOLYURETHANE FOAMWFLOAIR1 STRIP 4" x 16" x 1" THICKPOLYURETHANE FOAM7 STRIPS 4" x 30" x 1" THICKPOLYURETHANE FOAMFOR MODEL ESP-4860J11

FIGURE 2.14: MOUNTING PLATFORMS FOR VERTICAL INSTALLATIONSStep 5: Connecting Refrigerant LinesConnect refrigerant lines from the outdoor condensingunit to the fan coil unit in accordance with itsmanufacturer's sizing recommendations for the length ofthe piping run. Proper line sizing is critical to the operationof the system. Always use proper brazing procedures. A12trickle flow (2PSI) of dry nitrogen to avoid scale orblockage in the piping system is recommended whilebrazing. SpacePak also recommends installing a sightglass on the liquid line outside of the unit as an aid foraccurately charging the system.

Step 6: Installing the Condensate Trap & LineNOTICE: It is a requirement of the InternationalMechanical Code (307.2.3) to install a secondary drainor an auxiliary drain pan where damage to anybuilding components will occur as a result ofoverflow from the equipment drain pan or stoppage inthe condensate drain piping from a cooling or anevaporator coil. Follow local code requirements.NOTICE: The secondary drain connection requiresfield supplied components to complete installation.Follow local code requirements.NOTICE: Never connect condensate line to a closeddrain system.FIGURE 2.15: CONDENSATE TRAP ASSEMBLYRefer to Figure 2.2 and 2.3 for primary and secondarycondensate drain locations. Components for the PVCcondensate trap are provided in a separate bag with fancoil unit (see Figure 2.15) and should be cementedtogether with PVC pipe cement.1SEE NOTE54*Do not use substitute trap. Do not cutoff or alter trap components.32WG0127BThread male adapter (see Figure 2.9) into unit’s primarycondensate drain connection. Assemble and cementremaining components together. Then cement assemblyto male adapter. The 45 elbow provides an offset frombeneath unit suction line for access to clean-out plug.3/4'' P-TRAP ASS'Y KITITEMDESCRIPTIONMALE ADAPTER, 3/4''12ELBOW 45 ?, 3/4''TEE, 3/4''343/4'' X 1/2'' BUSHING51/2'' PLUGP-TRAP, 3/4''66NOTE: PIPE SECTIONS ARE FIELD SUPPLIED.Run a condensate line from the trap to a suitable drainthat’s in accordance with local codes. Make sure the lineis pitched 1/4" per foot.*SECOND 3/4" MALE ADAPTER SUPPLIED FOR OVERFLOW CONN ECTIONStep 7: Wiring the UnitTurn off electrical power supplybefore servicing. Contact with live electric components can cause shock or death.Locate the room thermostat on a wall near the return airbox, between 40" to 48" from the floor. Connect the lowvoltage thermostat wiring from the room thermostat tothe low voltage control block in the unit.All electrical and control wiring must be installed inaccordance with the codes listed in Section 1 of thismanual. Standard wiring diagram is provided in Figure2.16. Optional wiring diagrams are provided in Figures2.17-2.20. A separate 230/60/1 power supply isrecommended for the unit. Use standard 15-amp circuitbreaker and 14-gauge wire from power supply to unit.Connect low voltage from air handler to condensing unitas shown in figure 2.16.Alternately, the unit may be configured to run on115V, 60 Hz power. Refer to wiring diagram section.Connect power supply to Terminals L1 and L2 on thehigh voltage terminal block. Connect a ground wire tothe equipment ground terminal located next to the highvoltage terminal block.Step 8: Installing Air Distribution ComponentsAll plenum duct and supply tubing runs as well as roomterminator locations must be in accordance with airdistribution system requirements listed in Section 1 ofthis manual. Where taping of joints is required, UL181approved tape is required.Keep all tees and elbows to a minimum to keep systempressure 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.Plenum Duct InstallationAll tees, elbows and branch runs must be a minimum of 18"from the fan coil unit or any other tee, elbow or branch run.13

FIGURE 2.16: MODEL ESP-J 230V STANDARD WIRING DIAGRAM*ESP & WCSP 120V/230VTTBOILER/PUMPCONTROLCW1ALL TEMP SENSORS 10K NTC120VAC FIELD CONVERSIONTB1TB1PEL1WTBKPRIMARY COILRDPRIMARY 120VACSEC 24VACYLBLPRIMARY 240VACSEC ANSFORMERCONFIGURED FOR230VAC INPUTWTRDGNBK(FAN-4)240V120V -STAT C876521SEL16 15413 12 11 109UP120V FIELD CONVERSIONJUMPERL2NMOTOR CONTROLLCD BUTTONSLCD1U1124VAC J12TRANSFORMERCONFIGURED FOR120VAC INPUTP1J10WTBKGNRDPRESSURECOMG B- A G AIRSENSOREXTERNAL COIL(IF LKHUMIDIFIERIFINSTALLEDCONDENSATE FLOAT SWITCHCW1TTBOILER/PUMPCONTROL14

FIGURE 2.17: SINGLE STAGE AIR CONDITIONING ONLY WIRING DIAGRAMCOIL2LATCOIL1ESP 120V/230VSINGLE STAGEREFRIGERANTCONDENSER ONLYTEMPERATURE15

FIGURE 2.18: SINGLE STAGE AIR CONDITIONING WITH HW COIL WIRING DIAGRAMESP 120V/230V SINGLE STAGEREFRIGERANTCONDENSER WITHHW COIL/BOILER ORELECTRIC COIL2C

FIGURE 2.19: TWO STAGE HEAT PUMP/AC WIRING DIAGRAMCOIL2LATCOIL1ESP 120V/230VTWO STAGEHEAT PUMPREFRIGERANT CONDENSERTEMPERATURE17

FIGURE 2.20: TWO STAGE HEAT PUMP/AC WITH BACKUP BOILER HEAT WIRING DIAGRAMESP 120V/230VTWO STAGEREFRIGERANT CONDENSERWITH HW COIL/BOILER ORELECTRIC BACKUP IL2TTBOILER/PUMPCONTROLCW1

FIGURE 2.23: INCORRECT TUBING INSTALLATIONFIGURE 2.25: TERMINATOR MEASUREMENTSSOUNDATTENUATINGTUBE4" DIA.5"DRY WALLOR PLASTER5"Assemble spring clips to terminator plate with screwsprovided in installation kit. Tighten clips until they areclose to the thickness of the material they are beingmounted to.THIS RADIUSTOO SHORTTERMINATORSTUD SPACERoom Terminator & Sound AttenuatingTubing InstallationRoom terminators and pre-assembled soundattenuating tubes are provided in the Installation Kits.Assemble the room terminator to the sound attenuatingtubing by simply fitting the two pieces together andtwisting until tight (see Figure 2.24). If the terminator isto be used in a floor location, then field fabricate a smallscreen (1-1/2" square; 1/4 X 1/4 20-gauge galvanizedwire screen) and place screen over opening on theback of the terminator prior to twisting on the kwikconnect (on the sound attenuating tube).NOTICE: Do not install terminators in a wall in whicha sharp bend in the sound attenuating tube is required(see Figure 2.23). The result would be unacceptable noise.NOTICE: Do not shorten sound attenuating tubelength. The result would be unacceptable noise.OPTION: Using a SpacePak Kwik Connect WallElbow (Model Number: AC-KCWE) addresses thiscondition (see Figure 2.24).Push the free end of the sound attenuating tube throughthe 4" hole until the two toggle springs on the room terminator snap into place.FIGURE 2.24: INSTALLATION WITH KWIKCONNECT WALL ELBOWCenter the two spring clips on a line parallel to thedirection of the tubing routing from the room terminator(see Figure 2.26). This is important since the weight ofthe tubing will have a tendency to cause a part of theterminator to pull away from the ceiling if the clips andtubing do not run parallel.SOUND ATTENUATORSOUNDATTENUATORFOR APPLICATIONSFORAPP ICATIONSAPPICATIONS WITHWITHITHTHICKER WALLBOARDTHICKERWAL BOARDWALBOARD,BOARD,REMOVEREOVE MATERIAL FROMOVETHIS AREATHISA EAEA TO ALLALLOWW FORPROPER FIT.PROPERFIFIT.Then tighten the screws (attached to the terminator) untilthe terminator is snug against the ceiling or floor. Donot overtighten. For installations with floors or ceilingswhich are thicker than normal, longer toggle screws orspecial mounting plates may be required.3/16 GA3/16GAPINSULAINULATIONULATION 3/83/8 NOMINALNONOMINALMINALSHEET ROCKSHEETROCK3.5003.5005000.6250.625625FIGURE 2.26: POSITIONING ROOM TERMINATORSPL-0050-AIn marking location for room terminator (see Figure 2.25),the center of the terminator should be approximately 5"from the wall or, when installed in the corner of a room5" from both walls.After marking location, drill a 1/8" diameter hole foroutlet. Verify there is at least 2" for tubing assemblyclearance all around this hole by visual inspection orinserting 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, takea 4" diameter rotary-type hole saw and cut a hole, usingthe 1/8" diameter hole as a pilot.19INGUTROGNBITU

Supply Tubing InstallationKwik-connects and balancing orifices are provided in theInstallation Kits. Plenum take-offs, gaskets and fastenersare supplied in the separate plenum take-off kit.Avoid sharp bends in the supply tubing (as well as thesound attenuating tubing). The minimum radius bend is4" (see Figure 2.27); however, wherever possible, holdto a larger radius.FIGURE 2.27: MINIMUM TUBING BENDAfter attaching the supply tubing to the sound attenuatingtube, bring the open end of the tube to the plenum.To cut a hole in the plenum, refer to duct installationinstructions supplied with fan coil unit. Sheet metal ductrequires a 2-1/16" hole.FIGURE 2.29: CONNECTING TUBING4" MINIMUM RADIUSAt the plenum, all supply tubing connections must be aminimum of 18" from any plenum tee, plenum elbow orthe fan coil unit.Remove the ho

Central Air Conditioning Series 2 to 5 Tons Fan Coil Unit/Air Supply Components MODEL ESP-J & ESP-JV INSTALLATION, OPERATION & MAINTENANCE MANUAL ESPJ2-0620 45W30-WG1283. 2 SPACEPAK SYSTEM DESIGN SpacePak is a hi-velocity central air conditioning system which utilizes a conventional outdoor condensing unit