AIRINNOVATIONS HEPAir 24S050 User manual

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HEPAir
Installation, Operation
and Maintenance Manual
(Model shown may not be reflective of your model)
Manufactured by:
7000 Performance Drive
North Syracuse, NY 13212
Edition 10-2018
© Air Innovations 2018
Part No. 15H0222-00

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TABLE OF CONTENTS
Directory of Terms...........................................................................................................5
Receiving, Inspecting and Unpacking the HEPAir Unit....................................................6
Review the Packing Slip to Verify............................................................................................6
Check the unit for....................................................................................................................6
General Description.........................................................................................................7
Standard Specifications..................................................................................................8
The HEPAir Unit Contains ....................................................................................................8
Accessories and Optional Equipment..............................................................................9
Heating Coils ..........................................................................................................................9
Water Cooled Option ..............................................................................................................9
Duct Collars and Filters...........................................................................................................9
Humidifier and Humidistat.......................................................................................................9
Controls..................................................................................................................................9
Overview of the HEPAir Unit .......................................................................................10
General Overview Illustration of the HEPAir Unit ..................................................................11
Overview Illustration of water-cooled system ........................................................................12
Wiring Diagram for HEPAir ...................................................................................................13
Wiring Diagram for HEPAir with Remote Control ..................................................................14
HEPAir Dimensional Data.....................................................................................................15
HEPAir Dimensional Data.....................................................................................................16
HEPAir Specifications Sheet.................................................................................................17
HEPAir Specifications...........................................................................................................18
Safety ............................................................................................................................19
Safety Message Conventions .............................................................................................20
Danger..................................................................................................................................20
Warning................................................................................................................................20
Caution.................................................................................................................................20
Lockout/Tagout Procedure ..................................................................................................21
Safety Considerations...........................................................................................................21
Safety Hazards.....................................................................................................................21
Electrical Hazards.................................................................................................................21
Electrical Shock Hazards......................................................................................................21
Hot Parts Hazards ................................................................................................................21
Moving Parts Hazards...........................................................................................................22
Equipment Safety Interlocks .................................................................................................22
Main Power Switch ...............................................................................................................22
Installation .....................................................................................................................24
Pre-installation Test..............................................................................................................24
Air Flow Illustration................................................................................................................25
Planning the Installation.................................................................................................25
Addressing Items in the Planning Process............................................................................25

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Performing a Pre-installation Check......................................................................................26
Locating the Unit...................................................................................................................26
Grilles ...................................................................................................................................26
Reducing Noise from the Unit...............................................................................................26
Mounting the Unit ..........................................................................................................27
Floor Mounting......................................................................................................................27
Wall Mounting.......................................................................................................................27
Ceiling Mounting...................................................................................................................27
Installing the Condensate Drain Connection.........................................................................27
Installing the Drain Line ........................................................................................................28
Priming the Drain Trap..........................................................................................................28
Wiring the Unit for Power...............................................................................................28
Installing the 24v field supplied thermostat, if not PID control option.............................30
Installing the Ductwork and Grilles ................................................................................30
Recommended Insulated Flexible Ductwork Sizing Chart .................................................30
Location of Supply and Return Grilles...................................................................................31
General Duct Recommendation............................................................................................31
Using Ductwork.....................................................................................................................32
Cold Air to/from the Conditioned Space................................................................................32
Warm Air to/from Condenser ................................................................................................32
Duct Adapter Sizes........................................................................................................32
Ducting Options ...................................................................................................................33
Single Outlet Duct Installation .............................................................................................33
Inspection and Start-up Checklists................................................................................34
Receiving and Inspecting......................................................................................................34
Handling and Installing..........................................................................................................34
Starting-up the Unit...............................................................................................................34
Starting Up and Operating the HEPAir..........................................................................35
Turn on the Unit....................................................................................................................35
Running the Unit ..................................................................................................................35
Setting the Thermostat..........................................................................................................35
Regulating the Space to be Conditioned Temperature..........................................................35
Changing the Air Flow Direction............................................................................................35
HGBV (Hot Gas Bypass Valve).............................................................................................36
Maintenance..................................................................................................................37
General.................................................................................................................................37
Cleaning the Filters...............................................................................................................37
Cleaning the Condensate Drain System ...............................................................................38
Flushing a water regulating valve –water-cooled models only..............................................38
Cleaning the Humidifier (optional).........................................................................................38
Heating Coil Option...............................................................................................................38
Maintenance Schedule ................................................................................................39
Monthly.................................................................................................................................39
Yearly ...................................................................................................................................39

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Troubleshooting ............................................................................................................40
Typical Start-up Problems ...................................................................................................40
Unit Does Not Start-up ........................................................................................................40
Power Switch Light is Off......................................................................................................40
Power switch light is on and the thermostat light is off ..........................................................40
Power switch light is on and the thermostat light is on ..........................................................40
Unit is operating and blows evaporator air, ........................................................................41
Problems Controlling Space Temperature ............................................................................41
Space Temperature is too cold when unit is not running.......................................................41
Problems Controlling Space Humidity...................................................................................42
Humidity too low or supply air is too cold, without optional humidifier....................................42
Humidity too low, without optional humidifier.........................................................................42
Humidity too low with optional humidifier...............................................................................42
Humidity too high when unit is running but not cooling..........................................................42
Humidity too high when unit is not running............................................................................43
Humidity too high when unit is running and cooling...............................................................43
Other Miscellaneous Problems .............................................................................................43
Unit operates but the power switch light is not ON................................................................43
Unit is leaking water..............................................................................................................43
Unit is running properly, but the sound of the unit is objectionable........................................43
Noise is from airflow..............................................................................................................43
Redirect airflow.....................................................................................................................43
Basic Troubleshooting ............................................................................................44-45
Advanced Troubleshooting .....................................................................................46-47
High Pressure Switch has Shut Down the Unit ..........................................................48
Instructions to Reset High Pressure Switch .......................................................................48
Advanced Troubleshooting (continued).........................................................................49
Evaporator coil is freezing.....................................................................................................49
High pressure switch keeps tripping......................................................................................49
Unit cycles on and off more than 8 times/hr ..........................................................................49
High pitched or loud rubbing noise, clanking or vibration ......................................................49
Replacing the blowers...........................................................................................................49
Warranty........................................................................................................................50
Contact and Warranty Information.................................................................................51
Contact Information...............................................................................................................51
Warranty and Warranty Procedure .....................................................................................51

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Directory of Terms
Ambient Air –The surrounding area outside the space to be conditioned such as a room, basement,
garage or outdoors.
BTUH –British thermal units per hour.
CFM –Cubic feet per minute. A unit of measurement for the amount of air handled by the fan.
Condensate / Condensation –The water formed out of the air when it is cooled below a certain
temperature (called dew point). Often referred to as “sweating” on pipes and cold surfaces. This
water collects at the bottom of the evaporator or cooling coil and drains out of the unit through the
drain line.
Condenser (Heat Rejection) Section / Coil –The Condenser Section uses the compressor,
condenser coil and fan to remove heat from the refrigerant to the ambient air outside the controlled
space. The word condenser refers to the condensation of the refrigerant from gas to liquid phase.
CE–Certificate of European conformity
CSA/ETL –Canadian Standard Association/Electric Testing Laboratory
Exhaust Air –The air leaving the evaporator or condenser section of the HEPAir unit.
Evaporator (Cooling) Section / Coil –The Evaporator Section uses the cooling coil and the fan to
remove heat from the air inside the conditioned space to the refrigerant, cooling the air and condensing
moisture out of the air. The word evaporator refers to the evaporation of the refrigerant from liquid to
gas phase in the coil. The Evaporator Section is connected to or inside the space to be conditioned.
Flexible Duct –Round ducts with steel reinforced plastic liners, a layer of insulation and an outer
plastic layer used to convey the air from the unit to the conditioned space or ambient space.
Grille or Diffuser –Inlet or outlet plates to direct the airflow or protect the inside of the unit.
Heat Gain / Loss –The amount of cooling or heating expressed in watts or s transferred between the
conditioned space and the ambient space. The HEPAir must offset this load.
Inlet Air –The air entering the evaporator and condenser sections of the HEPAir unit.
Inlet Air –The air returning from the space to the HEPAir fan coil.
O.D. –Outside diameter
Psig Pounds –Force per square inch gauge
NEC –National Electrical Code
Recovery –The amount of cooling the unit does to return the space to its set point temperature after
some new load is introduced, such as people or new load entering the conditioned space.
Return Air - The air leaving the conditioned space and returning to the inlet of the evaporator coil.
SP –Static pressure. Unit of measurement (inches of water column) of the pressure of the air
handled by the fan.
Set Point –The desired temperature or humidity set on the thermostat or humidistat.
Supply Air - The air entering the conditioned space from the discharge of the evaporator coil.

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Receiving, Inspecting and Unpacking the HEPAir Unit
NOTE: HEPAir units are factory assembled and tested prior to shipment.
HEPAir units are shipped in individual corrugated boxes.
✓Lift at the designated handhold locations only or fully support from underneath. A
shipment may include one or more boxes containing accessories.
✓Before opening the container, inspect the packing crates or boxes for obvious signs
of damage or mishandling.
✓Write any discrepancy or visual damage on the bill of lading before signing.
✓Inspect all equipment for any sign of damage caused during transit.
✓Report all visual or concealed damage to the carrier and file a claim immediately.
✓Thoroughly inspect the contents for any visible damage or loose parts.
Review the Packing Slip to Verify
✓Model number
✓Factory installed options
✓Unit accessories
If any items listed on the packing slip do not match your order information, contact the
place of purchase immediately.
Check the unit for
✓An electrical power cord(s).
✓A drain line coming out of the unit
IMPORTANT
If this procedure is not followed,the shipping company may reject the claim and
the consignee may suffer the loss. Do not return the shipment to the factory.

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General Description
Refer to overview illustrations starting on page 12
The HEPAir is a self-contained air conditioning unit using R-134a refrigerant. HEPAir was
designed primarily for ease of installation, operation and service.
Conditioned air is discharged to the room while condenser air is discharged above the ceiling.
The unit is designed for use in a clean room, where environmental and tight tolerance
conditions are required. The unit can equally be applied to any area where ceiling mounted air
conditioning is required.
A typical HEPAir 24S200 is 49.50” x 22.38” x18” and is hung independently of the suspended
ceiling. HEPAir is available in 115/1/60, 208-230/1/60 or 220-240/1/50 power. Units are hard
wired, but a cord and plug may be provided as an option. Nominal unit capacities of ½, 1-ton
and 2-ton are offered.
Available options include PID digital controllers for precise applications, electric re-heat coils
and humidifiers.
The HEPAir is ETL IAW UL/CSA 1995 approved.
The HEPAir cooling unit is a professional grade, American manufactured, self-contained
climate control unit. It is designed for easy installation and operation. HEPAir uses digital
electronic controls and R-134a refrigerant. The entire unit is tested at the factory and shipped as
a single package. All components are of a high quality, standard commercial grade. The entire
unit is approved by ETL according to UL 1995 and CSA safety standards. All wiring complies
with NEC. Each unit is furnished with a sealed, UL-approved power cord and plug.
The HEPAir space cooling system is completely self-contained and includes either an integral
air cooled or water-cooled condenser. The units are functionally divided into two sections, the
evaporator (or cooling section) and the condenser (or heat rejection section). Each section
contains a coil to add or remove heat and a fan to move the air through the coil and into or out
of the space or adjacent space. The HEPAir cooling systems are designed to be used as a
remotely mounted unit with external ductwork connections.
Air first passes through the cooling coil and is cooled by the refrigerant inside the coil. This
causes any excess humidity in the air to condense and be captured in the drain pan and piped
outside the unit. Air then enters the fan where it is pressurized and discharged out of the unit.
Optional heating coils are located between the cooling coil and the fan. These coils heat the air
to maintain setpoints. The thermostat, located in the conditioned space, turns on the cooling or
heating as needed to maintain its setpoint. The cooling and heating can operate simultaneously
to maintain setpoint if set up for PID controls.
The compressor and condenser sections are activated whenever the unit is cooling. The
condenser fan draws air from the surrounding or ambient space either directly or through a
duct. The air is first drawn through a filter to remove any airborne dust particles to keep the
coil clean. The air flows through the condenser coil where it absorbs heat from the refrigerant
in the coil. The air is then discharged out of the unit by the condenser fan.

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The water-cooled HEPAir system requires cooling water to be piped to the unit for proper
operation. The cooling water absorbs the refrigerant heat through the unit’s water-cooled
condenser coil. Warm water is then directed out of the unit back to the cooling water system or
to a drain.
IMPORTANT
The air exhaust from the condenser fan on air-cooled units is hotand willbe 25 to 35 degrees F
(15 –18 degrees C) above the entering temperature. This may cause overheating problems in the
summer months, especially with high humidity. Exhaust the hot air to the outside. In the winter,
this heated air can help to heat the surrounding space.
Standard Specifications
NOTE: Design and specifications are subject to change without notice.
The HEPAir Unit Contains
✓A thermal expansion valve to control the flow of refrigerant into the evaporator coil
✓A manual reset high pressure switch to protect the system from high pressures
✓The unit uses only R-134a refrigerant
✓A built-in condensate drain trap. (no external trap is required)
✓A hot gas bypass valve for coil lat adjustment, as required (factory set)
The HEPAir 60Hz models meets or exceeds its rated capacities for total BTU/H and CFM at
design conditions and external static pressures. Both the evaporator and condenser fans are
capable of rated CFM against the external static pressure imposed by recommended ductwork.
Both fans are motorized impeller plug fans, statically and dynamically balanced, and use
permanently lubricated, direct drive motors that require no maintenance.
All exterior framing of the HEPAir unit is powder coated 0.063” (1.6mm) gauge aluminum to
prevent rust and corrosion. All coils are aluminum or copper tubes with aluminum fins. The unit
uses an external drain to remove excess moisture and not reintroduce it into the conditioned or
ambient space. Removable, multiple access doors are provided to facilitate cleaning and
maintenance, duct connections, and access to components and wiring.
The condenser coils have pre-filters on the inlet to prevent dust and dirt from fouling the coils,
thereby reducing capacity. Each unit has multiple discharge outlets on both the evaporator and the
condenser coils to facilitate custom installations. Water-cooled units have copper straight tube
connections for both cooling water inlet and outlet.
Each unit is provided with pre-wired, 24v controls compatibility and tested for remote mounting.
Compressors are self-lubricating, permanently sealed, hermetic reciprocating type compressors,
with internal overload protection and capacitor start. Compressors are mounted on rubber-in-shear
isolators to reduce noise and vibration.
Electric power is supplied by a furnished power cord(s).

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Accessories and Optional Equipment
Heating Coils
An optional heating coil is built-in and requires no additional power source. The electric heating
option is factory installed and includes primary and secondary over-temperature protection devices per
UL and NEC.
Water Cooled Option
A water-cooled option is available that uses a tube-in-tube heat exchanger in place of the condenser
coil and fan. Waste heat from the refrigerant is transferred to the water. A pressure regulating valve is
used to regulate the flow of water to maintain head pressure.
Duct Collars and Filters
Ducting for the HEPAir is sold as options by size for each unit. Each option contains duct collars, or
filter rack with filter. The number of options needed depends on the layout. The size of the collars or
filters depends on the model HEPAir selected. Follow installation instructions carefully. Poorly or
incorrectly installed ducts can degrade the performance of your unit dramatically.
Humidifier and Humidistat
Another popular option for the HEPAir is a humidifier. The humidifier is available as a separate unit
that is packaged remotely from any HEPAir ducted system. The HEPAir humidifier requires a water
supply and drain for operation.
CAUTION
CAREFULLY FOLLOW THE INSTALLATIONS INSTRUCTIONS INCLUDED WITHTHE HUMIDIFIER.
REFER TO THE INSTRUCTIONS CONTAINEDIN THE BOX FORTHE HUMIDISTAT.
Controls
Offered as a standard with 24v control compatible wiring for factory, or factory wired remote
mounted PID controls.

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Overview of the HEPAir Unit
Refer to overview illustrations starting on page 11
Cabinet – The cabinet and access doors are constructed of aluminum with a powder coated finish for
corrosion protection and an attractive, maintenance-free appearance. Areas in contact with cold
temperatures are lined with insulation to prevent condensation .
Condensing Section – Ambient air is circulated through the condenser section by a direct drive,
permanently lubricated, motorized impeller blower. This section also contains the compressor and
the electrical controls. If the water-cooled option is purchased, a heat exchanger is used in place of
the condenser coil and blower.
Evaporator Section – Conditioned air is circulated through the evaporator section by another
blower the same as above. The large evaporator coil face area eliminates condensate carry-over,
reduces air pressure drop and optimizes heat transfer. A drain pan is located directly below the coil
to capture condensate and is fabricated from aluminum to prevent rust and corrosion. The electric
heating coil, if ordered, is factory installed between the evaporator coil and the blower and is
complete with contactor(s) and limit controls.
Electrical Controls – Most of the electrical components and controls are located in a separate area
accessible on the side of the unit. All wiring is in accordance with the NEC. Wires are numbered and
color coded to match the wiring diagrams.
Factory Tested – All HEPAir units are factory run-tested and checked for operational performance.
Filters –Nominal 1-inch (25mm) thick filter is provided on the condenser inlet to protect the coils
from dust and dirt. This filter is washable and reusable.
Humidity Option – The optional humidifier comes fully assembled and tested for field installation
with the HEPAir without any additional electrical power wiring. It automatically adds moisture into
the space by the evaporation of water distributed.
Internal Drain Trap - Water condensate from the evaporator coil fills the trap and forms a seal to
prevent air from being drawn back through the drain tube. This allows the drain pan to drain freely.
No external trap is required.
Refrigerant Circuit –The factory charged circuit includes a thermal expansion valve with an
external equalizer, a filter dryer, and a manual reset high pressure switch. See Fig 1 - Refrigeration
Illustration on next page.
Supply/return grilles –Ap owder-coated steel single direction grille is provided on the outlet of
condenser section. One grille is provided on an outlet. The grille is interchangeable with access
doors to control and direct the airflow. These grilles may be used in the conditioned space on the end
of the ducts, as an option.