Engineered air PD SERIES User manual

IOM-39 Aug 99 R1
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
FOR
PD SERIES
PACKAGED POOL DEHUMIDIFICATION UNITS
INDOOR AND OUTDOOR MODELS
UNIT MODEL NO. ___________________
UNIT SERIAL NO. ___________________
SERVICED BY: _____________________
TEL. NO: __________________________
CANADIAN
HEAD OFFICE
AND FACTORY
USA
HEAD OFFICE
AND FACTORY
CANADIAN
EASTERN FACTORY
1401 HASTINGS CRES. SE
CALGARY, ALBERTA
T2G 4C8
Ph: [phone]
Fx: 888-364-2727
32050 W. 83r
d
STREET
DESOTO, KANSAS
66018
Ph: [phone]
Fx: [phone]
1175 TWINNEY DRIVE
NEWMARKET, ONTARIO
L3Y 5V7
Ph: [phone]
Fx: [phone]
SALES OFFICES ACROSS CANADA AND USA
Retain instructions with unit and maintain in a legible condition.
Please give model number and serial number when contacting
factory for information and/or parts.
www.engineeredair.com

APD MANUAL
IOM-39 2 of 36 Aug 99 R1
TABLEOFCONTENTS
You Have Responsibilities Too...........................................................................................................................................................3
Introduction.........................................................................................................................................................................................3
Safety Precautions..............................................................................................................................................................................3
Warranty.............................................................................................................................................................................................4
Parts...................................................................................................................................................................................................5
Receiving............................................................................................................................................................................................5
Temporary Storage............................................................................................................................................................................. 5
Installation ..........................................................................................................................................................................................6
Codes.................................................................................................................................................................................................6
Minimum Clearance To Combustibles And For Service In Inches (Mm)............................................................................................. 7
Clearance For Condenser Air Flow..................................................................................................................................................... 8
Lifting.................................................................................................................................................................................................. 8
Mounting............................................................................................................................................................................................. 9
Shipping Materials............................................................................................................................................................................ 10
Assembly.......................................................................................................................................................................................... 10
Split Unit Wiring.......................................................................................................................................................................10
Piping, Electrical Or Control Service Connections............................................................................................................................ 11
Electrical Installation......................................................................................................................................................................... 11
Recommended 24v Field Wiring Size.....................................................................................................................................12
Coil Connections............................................................................................................................................................................... 13
Drain Traps....................................................................................................................................................................................... 13
Flushing And Degreasing Of Water And Glycol Coils....................................................................................................................... 14
Heat Transfer Fluids................................................................................................................................................................14
Pool Water Piping ...................................................................................................................................................................15
Before Start-Up.................................................................................................................................................................................15
Start-Up Check List...........................................................................................................................................................................15
Operation..........................................................................................................................................................................................19
Cooling Components........................................................................................................................................................................19
Refrigerant Handling......................................................................................................................................................................... 21
Compressor Oil................................................................................................................................................................................. 22
Shutdown Procedure........................................................................................................................................................................ 22
Charging Instructions........................................................................................................................................................................ 23
Reheat Systems......................................................................................................................................................................23
Maintenance.....................................................................................................................................................................................25
Electrical........................................................................................................................................................................................... 25
Belt Adjustment ................................................................................................................................................................................ 25
Set Screws ....................................................................................................................................................................................... 26
Bearing Setscrew Torques ............................................................................................................................................................... 27
Lubrication Of Fan Bearings............................................................................................................................................................. 27
Lubrication Of Dodge Fan Bearings.................................................................................................................................................. 28
Motor Lubrication.............................................................................................................................................................................. 30
Filters................................................................................................................................................................................................ 30
Controls............................................................................................................................................................................................ 31
Control Enclosure Ventilation ........................................................................................................................................................... 31
Outdoor Air Intakes, Mixing Sections And Dampers......................................................................................................................... 31
Coils.................................................................................................................................................................................................. 32
Coil Winterization....................................................................................................................................................................32
Coating Maintenance........................................................................................................................................................................ 32
Heating....................................................................................................................................................................................33
Refrigeration..................................................................................................................................................................................... 33
Trouble Shooting ..............................................................................................................................................................................35
Start Up Record................................................................................................................................................................................36

©AirtexManufacturingPartnership.Allrightsreserved.

APD MANUAL
IOM-39 3 of 36 Aug 99 R1
YOUHAVERESPONSIBILITIESTOO
Thisinstallation,operationandmaintenancemanualcannotcovereverypossibility,situationor
eventuality.Regularservice,cleaningandmaintainingtheequipmentisnecessary.Ifyouarenotcapable
ofperformingthesetasks,hireaqualifiedservicespecialist.Failuretoperformthesedutiescancause
propertydamageand/orharmtothebuildingoccupantsandwillvoidthemanufacturers’warranty.
INTRODUCTION
EngineeredAirunitsarehighqualityproductsdesignedandmanufacturedtoprovidemanyyearsof
trouble‐freeoperation.Werecommendthatthismanualbereadthoroughlytoensureproperinstallation,
efficientoperationandpropermaintenanceofthisequipment.Thesubmittalrecordisconsideredtobe
partoftheInstallation,OperationandMaintenanceManual.Pleasereportanyomissionstothenational
servicemanager.

Natatoriums(Indoorswimmingfacilities)haveinherentissueswithhighrelativehumiditywithinthe
buildingenvelope.Excessivehumiditywithinastructurecancompromisethebuildingintegrityorpromote
thegrowthofmoldandmildew.Itisnecessarytocontroltherelativehumiditytominimizetheassociated
problems.Theprimaryfunctionofapooldehumidifier(PDseriesunit)istomanagethehumiditylevels
withinthefacilities.Thishelpstoreducetheadverseeffectsofhighhumidityonthebuilding.
Additionalfunctionsforthepooldehumidifiermayincludespaceventilation,comfortheatingand/or
coolingandpoolwaterheating.

ControlisnormallyaccomplishedbymeasuringthesensibleroomtemperatureandtheRH%.Thisisthen
calculatedbythecontrollertodeterminethedewpoint.

SAFETYPRECAUTIONS
Read,understandandfollowthecompletemanualbeforebeginningtheinstallation,includingallsafety
precautionsandwarnings.
Warning:

Improperinstallation,adjustment,alteration,serviceormaintenancecancause
propertydamage,injuryordeath.Readtheinstallation,operatingandmaintenance
instructionsthoroughlybeforeinstallingorservicingthisequipment.
Warning:Thisunitisconnectedtohighvoltages.Electricalshockordeathcouldoccurif
instructionsarenotfollowed.Thisequipmentcontainsmovingpartsthatcanstart
unexpectedly.Injuryordeathcouldoccurifinstructionsarenotfollowed.Allwork
shouldbeperformedbyaqualifiedtechnician.Alwaysdisconnectandlockoutpower
beforeservicing.DONOTbypassanyinterlockorsafetyswitchesunderany
circumstances.



APD MANUAL
IOM-39 4 of 36 Aug 99 R1
WARRANTY
LIMITEDWARRANTYENGINEEREDAIRwillfurnishwithoutcharge,F.O.B.factory,freightcollect,
replacementpartsfor,orrepairstoproductscoveredhereinwhichprovedefectiveinmaterialor
workmanshipundernormalandproperuseforaperiodoftwelve(12)monthsfromtheinitialstart‐upor
eighteen(18)monthsfromthedateofshipment,whicheverexpiressooner,providedthecustomergives
ENGINEEREDAIRwrittennoticeofsuchdefectswithinsuchtimeperiodsandprovidedthatinspectionby
ENGINEEREDAIRestablishesthevalidityoftheclaimandallpertinentinvoiceshavebeenpaidinfull.The
repairsorreplacementswillbemadeonlywhenthecompleteproduct(s)orpart(s)claimedtobedefective
arereturnedtoENGINEEREDAIRoradepotdesignatedbyENGINEEREDAIR,transportationcharges
prepaid.Repairsorreplacementsasprovidedforbythisparagraphshallconstitutefulfillmentofall
ENGINEEREDAIR'sobligationswithrespecttothiswarranty.Therefrigerantchargeisnotincludedinany
partofthiswarranty.Thiswarrantydoesnotapplytoanyproductsorpartsthereofthathavebeensubject
toaccident,misuseorunauthorizedalterations,orwhereENGINEEREDAIR'sinstallationandservice
requirementshavenotbeenmet.

Theforegoingwarrantyisinlieuofallotherwarranties,expressorimplied.ENGINEEREDAIRspecifically
disclaimsanyimpliedwarrantyofmerchantabilityand/orfitnessforpurpose.Undernocircumstances
shallENGINEEREDAIRbeliableto,norberequiredtoindemnify,Buyeroranythirdpartiesforanyclaims,
losses,labor,expensesordamages(includingspecial,indirect,incidental,orconsequentialdamages)of
anykind,resultingfromtheperformance(orlackthereof)ofthisAgreementortheuseof,orinabilityto
usethegoodssoldhereunder,including,butnotlimitedto,damagesfordelay,temporaryheating/cooling
costs,lossofgoodwill,lossofprofitsorlossofuse.Furthermore,thepartiesagreethattheBuyer'ssole
remedyunderthisAgreementshallbelimitedtothelimitedwarrantysetforthintheprecedingparagraph
relatingtotherepairorreplacementofanydefectivegoods.Undernocircumstancesshallanyclaimor
awardagainstENGINEEREDAIRexceedtheoriginalcontractpricewhetherawardedthrougharbitration,
litigationorotherwise.

ENGINEEREDAIRWarrantyisvoidif:

1. Theunitisnotinstalledinaccordancewiththismanual.
2. Thestart‐upandoperationoftheunitisnotperformedinaccordancewiththismanual.
3. Theunitisallowedtooperateduringbuildingconstruction.

APD MANUAL
IOM-39 5 of 36 Aug 99 R1
PARTS
Warning:


Anyreplacementpartmustbeofequivalentlistingorcertificationandbefunctionally
equivalent.Thereplacementpartmustmeettheoriginal’sspecificationintermsof
functionalityincludingcertifications,timing,inputandoutputrange,accuracyand
operation.
Failuretoreplacepartsorcomponentswithequivalentpartscancauseproperty
damage,injuryordeath.
1. Motors:
Motormanufacturershaveservicecentersthatwillrepairorreplacemotorsasrequired.

2. PartsOtherThanMotors:
ContactthenearestEngineeredAirsalesofficeorfactory.BesuretoincludeModelNumber,Serial
Number,dateofinstallationandnatureoffailurealongwiththedescriptionofthepartsrequired.
Somepartsmaynotbestockeditemsthatmustbemadeorordered.
RECEIVING

Refertothebackofthepackingslipforreceivingunitinstructions.

Onreceiptoftheunit,checkfordamage.Inspectprotectivecoversforpuncturesorothersignsthatthere
maybeinternaldamage.Removeprotectivecoversandcheckforinternaldamage.Replacecoversifthe
unitisnotbeingassembledorinstalledatthistime.Openaccessdoorsandcheckforinternaldamage.
Closeaccessdoorswhentheinspectioniscomplete.

Allunitsarepre‐testedatthefactoryimmediatelypriortoshippingandareensuredtobeingood
operatingconditionatthattime.Ifdamageisfoundfollowtheinstructionsonthepackingslip.

Onreceiptoftheunit,checkelectricalcharacteristics(seeratingplate)tomakesuretheunitvoltageis
compatiblewiththatavailablefortheunit.Allpartsforfieldinstallationarelistedontheshippingorder
form.
TEMPORARYSTORAGE

Ifaunitistobestoredpriortoinstallationthefollowingprecautionsarerequired:
• Storeinawelldrainedareathatwillnotaccumulatesurfacewater.
• Storeinanareawheretheunitwillnotgetdamaged.
• Theentireperimeterandanyfullheightcrossmembersoftheunitmustbesupportedbyalevel
surfaceandthesupportingsurfacemustbeadequateforsupportingtheentireweightoftheunit.
• Allprotectivecoveringsthatwereprovidedforshippingmustbeinplace.
• Protectindoorunitsfromrainandsnow.

APD MANUAL
IOM-39 6 of 36 Aug 99 R1
INSTALLATION
Warning:OnlyequipmentbearingaCSAC22.2No.213orUL1604ratingplate(label)withan
accompanyingCSACertificationmarkissuitableforinstallationinahazardous
location.ThehazardouslocationmustconformwiththeClass,Division,Groupand
temperaturecode(ifshown)displayedontheratingplate(label).
Ifnotmarkedasnotedabove,theunitisnotratedforhazardouslocationsandshould
notbeinstalledinareasrequiringanyhazardouslocationrating.
 
Caution:
Allwiring,pipingandfuellineinstallationmustbecompletedbyqualifiedpersonsin
accordancewithallfederal,state,provincialand/orlocalcodes.

Note:Installationshallbeinaccordancewiththismanualandallotherassociatedcomponentand
controlInstallation,OperationandMaintenanceManuals.
CODES

InCanada:

1. TheinstallationofthisunitshallbeinaccordancewiththelatesteditionoftheCanadianElectrical
Code,Part1–C.S.A.StandardC22.1,ProvincialandLocalCodes,andinaccordancewiththelocal
authoritieshavingjurisdiction.

2. ThisunitshallbeelectricallygroundedinaccordancewiththelatesteditionoftheCanadian
ElectricalCode,Part1–C.S.A.StandardC22.1,ProvincialandLocalCodes,andinaccordancewith
thelocalauthoritieshavingjurisdiction.

3. TheinstallationofthisunitshallbeinaccordancewiththelatesteditionoftheNationalPlumbing
CodeofCanada,ProvincialandLocalCodes,andinaccordancewiththelocalauthoritieshaving
jurisdiction.

4. TheinstallationofthisunitshallbeinaccordancewithallotherNational,ProvincialandLocal
Codes,andinaccordancewiththelocalauthoritieshavingjurisdiction.


InUSA:

1. TheinstallationofthisunitshallbeinaccordancewiththelatesteditionoftheNationalElectrical
Code(ANSI/NFPA70),StateandLocalCodesandinaccordancewiththelocalauthoritieshaving
jurisdiction.

2. ThisunitshallbeelectricallygroundedinaccordancewiththelatesteditionoftheNational
ElectricalCode(ANSI/NFPA70),StateandLocalCodesandinaccordancewiththelocalauthorities

APD MANUAL
IOM-39 7 of 36 Aug 99 R1
havingjurisdiction.

3. Iftheunithasnotbeenprovidedwithanelectricdisconnectswitch,oneofadequateampacity
shallbeinstalledinaccordancewithArticle430oftheNationalElectricalCode(ANSI/NFPA70).

4. TheinstallationofthisunitshallbeinaccordancewiththelatesteditionoftheNationalStandard
PlumbingCode(NSPC),StateandLocalCodesandinaccordancewiththelocalauthoritieshaving
jurisdiction.

5. TheinstallationofthisunitshallbeinaccordancewithallotherNational,StateandLocalCodes,
andinaccordancewiththelocalauthoritieshavingjurisdiction.

MINIMUMCLEARANCETOCOMBUSTIBLESANDFORSERVICEININCHES(mm)
MODEL
COMBUSTIBLECLEARANCESERVICECLEARANCE
TOPFRONTBACKSIDEBOTTOMSERVICESIDECONTROL
PANEL†
ELECTRICHEAT1"(25)1"(25)6"(152)1"(25) 0UNITWIDTH+
10"(254)42"(1067)
FLUIDCOILS&
RECOVERYDEVICES1"(25)1"(25)1"(25)1"(25) 0UNITWIDTH42"(1067)
OTHERUNITS1"(25)1"(25)1"(25)1"(25) 024"(610)42"(1067)

†‐AsrequiredbytheCanadianElectricalCodeortheNationalElectricalCode.
ForSafetyandService,theminimumclearancesmustbeobserved.

APD MANUAL
IOM-39 8 of 36 Aug 99 R1
CLEARANCEFORCONDENSERAIRFLOW
Properairflowisessentialfortheoperationofthisequipment.Maintainatleast60”(1500mm)clearance
betweenthecondensercoilandanyobstruction.Maintainatleast96”(2400mm)betweenadjacent
condensingsections.Donotplacecondensersectionsinawell.Wellscreateasituationwhereairre‐
circulatesfromthecondenserfanbacktothecondensercoil.Enclosuresmustbedesignedforproperair
flowandtopreventblockageorre‐circulatedair.
LIFTING

EngineeredAirunitsareconstructedonastructuralsteelbaseframe.Theunitbaseframeisequipped
withliftinglugsspecificallylocatedtofacilitateproperliftingoftheunit.Spreaderbarsmustbeusedto
keepriggingawayfromtheunitcabinetry.Allliftinglugsmustbeused.Ifusingalifttruck,ONLYliftusing
theperimeterstructuralframe.DONOTallowforkstoliftoncabinetorunitfloor.
Note:Theremaybebottommountedcomponents,suchasdrainpiping,thatcanbeeasilydamaged.


1524
60" (MIN)
1524
60" (MIN)
60" (MIN)
1524
CURB OR SUPPORT
1219mm
48" (MIN)
1219mm
48"(MIN)
12" (MIN)
305mm
DO NOT OBSTRUCT
CANTILEVERED SECTION
DO NOT OBSTRUCT
CANTILEVERED COND. SECTION
ENCLOSURE OR
OBSTRUCTION
CURB OR SUPPORTCURB OR SUPPORT
ELEVATION VIEW
ELEVATION VIEW
PLAN VIEW
2438mm
96" (MIN)

APD MANUAL
IOM-39 9 of 36 Aug 99 R1
Warning:Injuryordeathcanresultfromimproperriggingandlifting.Riggingandliftingof
equipmentmustbeperformedbyqualifiedpersonnelwithproperequipmentusing
appropriateandapprovedsafetyprecautions.

MOUNTING

Unitsmustbemountedlevel.Failuretodosocancausewatertobetrappedindrainpansoroperational
problemsthatcanvoidwarranty.Failuretodosocanresultininjuryordeath,damagetheequipment
and/orbuildingandcanbeacauseofpoorindoorairquality.
Equipmentmustbeinstalledsothatsufficientworkingclearanceandcomponentaccessisprovided.
Someunitsaredesignedforcantileveredinstallation.ConsulttheSubmittalRecordforspecificunit
mounting.

ConsulttheSubmittalRecordforspecificunitmounting.EngineeredAirunitsareconstructedforthree
typesofmounting:

1. Basemounting–ConsulttheSubmittalRecordfortypeofmounting.Unlesstheunitisspecifically
designedforpointorothermounting,thebaseoftheunitmustbesupportedcontinuouslybya
mountingsupportsystemthatisdirectlybelowtheunitstructuralbaseframeandrunstheentire
lengthandwidthoftheunit.RefertotheSubmittalRecordformountinginformation.Units100”
(2500mm)wideandundercanbesupportedoneachsidecontinuouslyalongthelengthofthe
unit.Asaminimum,sleepersthatareinstalledperpendiculartothelengthoftheunitmustbe
continuousacrossthewidthoftheunitandshallbeinstalledattheendliftingpointbaserailsand
thelesserof80”(2000mm)oncenteroratallliftingpoints.

2. Suspendedmounting–Whereunitshavebeendesignedforsuspendedmounting,factoryprovided
connectionsforhangerrodswillbeprovided.Allhangerrodsupportsmustbeused.Suspended
unitsmustbeprotectedfromdamage.Wheninstalledinaircrafthangers,parkinggaragesor
repairgaragestheinstallationmustcomplywhereapplicablewith:

a) TheCanadianNaturalGasandPropaneInstallationCode,C.S.A.StandardB149.1
b) TheStandardonAircraftHangers,ANSI/NFPA409
c) TheStandardonParkingGarages,ANSI/NFPA88A
d) TheStandardonRepairGarages,ANSI/NFPA88B

3. Roofcurbmounting–Thecurbsareconstructedofheavygaugeloadbearing,galvanizedsteel,and
mustbefullyinsulatedafterinstallation.Woodnailerstripsareprovidedforeasyattachmentof
roofflashing.Gasketmaterialissuppliedwiththeunitandmustbefieldmountedonthecurbto
sealthejointbetweenthecurbandtheunitframe.Thecurbmustbesupportedalongitsentire
perimeterandanyfullheightcrossmembersasshownontheshopdrawings.Pointloadingof
curbsisnotpermissible.

Thegasketmaterialprovidedforthecurbisclosedcellfoam.Closedcellfoamisdenseanddoes
notcompresseasily.Iftheunitissplitandshippedinsectionstherewillalsobegasketmaterialfor

APD MANUAL
IOM-39 10 of 36 Aug 99 R1
sealingbetweensections.Thegasketmaterialforsplitsisopencellfoam.Itislessdensethanthe
closedcellfoamandcompresseseasily.
ONLYUSETHECLOSEDCELLFOAMGASKETPROVIDEDFORSEALINGTHECURB.

Curbsmaybebrokendownforshipping.Fieldassemblyisrequiredbytheinstallingcontractor.
Boltallsectionstogetheratsplitjointsusinghardwareprovided.Theinstallingcontractormust
caulkandsealalljointandcornerflashings.Allflashingsandbracesthatareprovidedmustbe
installed.DONOTscrew/penetratejoint,corneroradaptorflashings.Refertoassembly
instructionssentwithroofcurb.
SHIPPINGMATERIALS

Removeshippingmaterials.Shippingmaterialsmayinclude,butarenotlimitedto:
• Protectivecoversoveropenings,inlets,condensercoilsetc.
• Protectivecoversoversplitsectionsifprovided.
• Tie‐downbolts,strapsandblocksonfanandcompressorvibrationisolators.
• Tie‐downbolts,strapsandblocksontiltequippedheatpipesandenthalpy/desiccantwheelsif
supplied.
• Indirectfiredheatexchangersmaybesupportedwithwoodforshipping.Remove.
ASSEMBLY

Warning:Assemblyofsplitunitsrequiresboltingtogetherthebaseframeofadjacentsections.
Thismayrequirepersonneltoworkundertheunitduringassembly.Injuryordeathcan
resultfromimpropersupportorimproperloadingofthecurb.Additionaltemporary
supportshallbeprovidedbytheinstallerforthesafetyofpersonnel.


Iftheunitissplitandshippedinsections,thesectionsmustbefieldassembled.Allsectionsarepre‐drilled
forassembly.Thehardwareandgasketsarepackedinoneofthesections.Applythegasket,alignthe
sections.Thebaseframemustbeboltedtogetherfirst.Accessbelowtheunitforboltingofthebase
framemustbeprovided.Oncethebaseframehasbeentightlyfastened,looselyassembleallthebolts
andnuts,andthentighten.Caulkallsplitlines.Installsplitjointcaps.Theinlethoodisdesignedforfield
installation.Onoutdoorunitsconnectthehoodtothesupportflangeandattachwithappropriate
fasteners.Connectallwiringonunitsthathadbeensplitforshipment.

SPLITUNITWIRING

Allsplitwiringmustbecompletedbyanelectricianpriortostartingtheequipment.Anumberofdifferent
methodsareusedtoreconnectthewiring.

Powerwire:thiswiringisgenerallynotbrokenorspliced,andwillextendfromthedevicebacktothe
contactororterminalblockinsidetheelectricalpanel(s).Thewirewillbetaggedtoidentifywhichpanelit
extendstoandwillbenumberedtothecorrespondingconnection.


APD MANUAL
IOM-39 11 of 36 Aug 99 R1
Thelocationoftheequipmentsplitlinemayresultinthewirebeingdisconnectedatthedeviceitis
feeding.Thewirebundlewillbetaggedandidentified.Confirmcorrectrotationof3phasedevicesafter
thewiringconnectionshasbeencompleted.

Controlwire:thiswireistypicallybrokennearthesplitline,tobereconnectedateitheraenclosed
terminalblock,junctionboxorextendedtoanearbycontrolpanel.Eachwireorwirebundlewillbe
taggedandnumberedtoindicatethelocationitissentto.

Sensorwireshield:Thedrainwirefromtheshieldmustbegrounded(atoneendonly).Aground
connectionpointisavailableforconnectionatthepointoftermination.

Allloosewiringmustbesecurelyfastenedtotheequipmentcasinguponcompletion.
PIPING,ELECTRICALORCONTROLSERVICECONNECTIONS
DONOTinstallanythingthatwillinterferewithequipmentaccessortheratingplate.

EngineeredAirequipmentisconstructedwithcabinetandfloorsdesignedtopreventwaterfromentering
thebuildingthroughtheinstalledunit.Whenordered,factoryinstalledpipechasesand/orelectrical
chasesarebuiltintotheunitfloor.Factorychasesareprovidedwithcoversthatneedtobereplacedand
sealedafterpipingandelectricalconnectionsaremade.

Allpenetrationsthroughtheunitwallsmustbecaulkedandsealedtopreventairand/orwaterfrom
enteringtheunit.

ELECTRICALINSTALLATION

DONOTinstallanythingthatwillinterferewithequipmentaccessortheratingplate.

TheunitmustbeelectricallygroundedandallwiringmustbeinstalledinaccordancewiththeNational
ElectricalCode,ANSI/NFPA70,and/ortheCanadianElectricCodeCSA22‐1andtotheapprovalofthe
authoritieshavingjurisdiction.THEFLOOROFTHEUNITHASBEENMADEWATER‐RESISTANT.DONOT
CUTORDRILLHOLESINTHEFLOORORUSEPENETRATINGFASTENERS.Fieldwiringdiagrams,internal
wiringdiagramsandoperatingfunctionsareincludedinthecontrolcabinet.Thepowerrequirementsare
indicatedontheratingplate.Wherefieldwiringofcontrolcircuitsisrequired,takecaretosizethefield
wiringforamaximum10%voltagedrop.Thecontrolcircuitampacityisnotedonthefieldwiringdiagram.
Seethefieldwiringdiagramforrequirementsforshieldedortwistedpairwireforsolidstatedevices.








APD MANUAL
IOM-39 12 of 36 Aug 99 R1
Caution:TemporaryPowerGeneration
Thewarrantywillbevoidifthevoltagebeingfedfromanytemporarygeneratorisnot
within10%ofthenominalratednameplatevoltageandvoltageimbalanceshallbe
limitedto2%.Apowermonitorshallbeinstalledbyotherstoproperlymonitorpower
qualityandconditions.
Allgeneratorsetsshallbeprovidedwithovercurrentandearth‐faultprotection.The
protectiveapparatusshouldbecapableofinterrupting,withoutdamage,anyshort‐
circuitcurrentthatmayoccur.


Warning:
Nounspecifiedexternalloadshallbeaddedtothecontroltransformercircuit(s)orto
themainpowercircuit(s).


RECOMMENDED24VFIELDWIRINGSIZE

Copperconductorsonly
Circuit
Load
(Amps)
(1)
MaximumTotalLengthofRun
<50Ft<100Ft<150Ft<200Ft <250Ft <300Ft <350Ft <400Ft<450Ft <500Ft
(~15m)(~30m)(~45m)(~60m) (~75m) (~90m) (~105m) (~120m)(~135m) (~150m)
116AWG16AWG16AWG16AWG 16AWG 16AWG 14AWG 14AWG14AWG 12AWG
216AWG16AWG16AWG14AWG 12AWG 12AWG 12AWG 10AWG10AWG 10AWG
316AWG16AWG14AWG12AWG 12AWG 10AWG 10AWG 10AWG  
416AWG14AWG12AWG10AWG 10AWG 10AWG    
516AWG12AWG12AWG10AWG      
616AWG12AWG10AWG10AWG      
714AWG12AWG10AWG       
814AWG10AWG10AWG       
914AWG10AWG        
1012AWG10AWG        
1112AWG10AWG        
1212AWG10AWG        
1312AWG         
1412AWG         
1512AWG         

Notes:
1) Thefieldwiringloaddependsontheactualloadonaparticularcontrolcircuitthefieldwiringis
connectedto.Refertotheinternalwiringdiagramoftheunit.
2) Thetableaboveisbasedonamaximum10%voltagedropona24Vcontrolcircuit.Wiresizewas
calculatedusingthefollowingformula:
CM=(25xIxL)/V


APD MANUAL
IOM-39 13 of 36 Aug 99 R1
WhereCMiscircularmilsofconductorforaconstantloadofIamps,wirelengthLinfeetfromthe
unittothefielddeviceandback,andvoltagedropV.

Whenconnectingtoathreephasepowersupply,checkforthecorrectrotationofallmotorsandfans.If
therotationisincorrect,reversetherotationattheincomingpoweronly.Allelectricalconduitoutletsin
thecontrolpanelmustbesealedtopreventmoistbuildingairfrommigratingtothecontrolpanel.

Allpenetrationsthroughtheunitwallsmustbecaulkedandsealedtopreventairand/orwaterfrom
enteringtheunit.
COILCONNECTIONS

Thisequipmentmayrequirefieldconnectionofwater,steamorrefrigerantcoils.Forproperoperation
airflowmustbecounterflowtotheflowofthefluid.Theinletwaterconnectionisnormallyatthebottom
ofoneheaderandtheoutletwaterconnectionatthetopoftheotherheader.Thesteamconnectionisat
themiddleofthesupplyheaderandthecondensateisatthebottomoftheotherheader.

Caution:
Useabackupwrenchonthreadedcoilconnectionswheninstallingpiping.


Forrefrigerantcoils,allpipingistobeinstalledbyaqualifiedrefrigerationmechanic.Allrefrigeration
specialtiesshallbeinstalledusinggoodrefrigerationinstallationanddesignpractices.

Recovery,reuse,recycling,reclamation,andsafedisposalofrefrigerantistheonlyacceptablepractice
today.Ventingofrefrigerantintotheatmosphereduringinstallationorservicingisunacceptable.To
avoiddamage,useanacceptedrefrigerantrecoverysystemwheneverremovingrefrigerant.When
workingwithrefrigerantsyoumustcomplywithalllocalgovernmentsafetyandenvironmentallaws.
DRAINTRAPS

Eachdrainconnectionrequiresaseparatedraintrapsuppliedandinstalledbythecontractor.Foratrapto
workproperly,itmustbeprimed.Duringfreezingperiods,primedtrapsmayneedtobeheattracedor
drainandplugthetrapwhennotinuse.Ifadrainconnectionhasasmallerpipeinside,connecttothe
outerpipeonly.Ensurethatthetrapisofadequatedepthtooperateagainstastaticthatincludesthe
extrapressuredropfordirtyfilters.
Warning:
Failuretoproperlytrapeachconnectioncanresultindrainpanflooding,standingwater
inunit,buildingdamage,injuryordeath,causepoorairqualityorotherproblems.


APD MANUAL
IOM-39 14 of 36 Aug 99 R1
Insomeapplications(e.g.heatrecoveryunits)theremaybeadditionaldrainconnectionsinsidethecurb
intendedtobeconnectedtothebuildingdrainagesystem.Thesedrainsmustbeconnectedandproperly
trapped.

Coolingcoildrainpansmayhavemultipledrainconnectionsextendingoutsidetheunitcasing.Multiple
drainsmaybeconnectedtoacommondrainprovidingthateachdrainisindividuallytrappedandvented
toavoidproblemsfromdrainsindifferentpressurezones.Thedrainmustbeproperlysizedandsloped.
Sizedraintrapwiththefollowingminimumrequirements:

a) UnitsWithDrawThroughDrainPans:

H1=NegativeStatic†x1.5+3.5”
(89mm)
H2=NegativeStatic†x0.75+2.5”
(64mm)


b) UnitsWithBlowThroughDrainPans:

H2=MaximumPositiveStatic†x1.5
H1=H2+0.5”(13mm)

†StaticWaterColumn(WC)ininchesormmincludingfullyloadedfilters.


Ensureadequateclearanceforproperlysizeddraintraps.
FLUSHINGANDDEGREASINGOFWATERANDGLYCOLCOILS

Coiltubingmaycontainmaterialorresiduefrommanufacturing,transportationorstorage.Toprevent
possibledamagetoothercomponentsinthesystem,thecoilsmustbeflushedanddegreased.Consulta
qualifiedwatertreatmentspecialist.

HEATTRANSFERFLUIDS

Thecoil(s)providedhavebeenselectedforusewithaspecificheattransferfluidasshownonthe
SubmittalRecord.Useofotherfluidswillresultindifferentperformanceandcandamagethecoil(s).

Itisimperativetoproperlyselectandapplyheattransferfluidsusedinheatingandcoolingsystems.
Untreated,improperlytreatedorimproperuseoffluidsoruseoffluidsnotapprovedforusein
commercialheatingandcoolingsystemscandamagecoilsandsystemcomponents.Forselectionand
applicationofheattransferfluids,alwaysfollowthemanufacturers’recommendationsincluding
treatment,mixingandfilling.Warrantywillbevoidifcoildamageresultsfrommisapplicationorimproper
treatmentoftheheattransferfluid.

H1
H2
H1
H2
VENT & PRIMING
FUNNEL
TO DRAIN
OPTIONAL
CLEAN OUT
ATMOSPHERIC

APD MANUAL
IOM-39 15 of 36 Aug 99 R1
SomesystemsmayuseCPVCpiping.DonotusepropyleneglycolwithCPVC.

POOLWATERPIPING

Somesystemsmayincorporateaheatexchangertorejectheattothepoolwater.Thepoolwaterpiping
shouldbeconsideredaspotablewater.Useproperpipingmaterialsforpoolwater.
BEFORESTART‐UP

Removetie‐downbolts,strapsandblocksonfanandcompressorvibrationisolators,tiltequippedheat
pipesandenthalpy/desiccantwheelsifsupplied.Ensureallopeningcoversareremoved.

START‐UPCHECKLIST

Warning:Thisunitisconnectedtohighvoltages.Electricalshockordeathcouldoccurif
instructionsarenotfollowed.Thisequipmentcontainsmovingpartsthatcanstart
unexpectedly.Injuryordeathcouldoccurifinstructionsarenotfollowed.Allwork
shouldbeperformedbyaqualifiedtechnician.Alwaysdisconnectandlockoutpower
beforeservicing.DONOTbypassanyinterlockorsafetyswitchesunderany
circumstances.



Thestart‐upandoperationmustbeinaccordancewithsafepractices.Start‐upmustbeperformedby
qualifiedpersonnel.Completeattachedstart‐uprecord.

1. Setallassociatedelectricalswitches,controls,thermostatsandmaindisconnectswitchto“OFF”
position.

2. Closeallmanualvalvesandfieldpipingvalves.

3. Beforestartup,reviewtheUnitFunction(mountedonthecontrolpaneldoor)andallcontrol
manualssuppliedwiththisequipment.Onunitswithheatingsections,pleasefollowthestart‐up
procedureintheheatingmanuals.(Pack,DJ,DG,RT,HE,LM‐Ketc.)

4. Confirmallshippingmaterialshasbeenremoved.Onunitswithsemi‐hermeticcompressors,
removefourspringisolatorspacersandbackoffthetopnutsothatthereis1/32"(0.8mm)to
1/16"(1.6mm)spacebetweenthenutandneoprenespacer.

5. Checkallbearings,driveandfansetscrewsfortightness.Seepage26.

6. Checkdrivealignmentandbelttension.RefertoMaintenance,page25.

7. Ensurethatrefrigerantlinesandcontrolcapillarylinesdonotrubagainstcabinetorotherlines.


APD MANUAL
IOM-39 16 of 36 Aug 99 R1
8. Inspectallelectricalwiring,bothfieldandfactoryinstalled,forlooseconnections.Ensurefirealarm
contactisinstalled,orjumperedifnotrequired.

9. TurndisconnectswitchON(controlswitchisstilloff)andcheckthesupplyvoltage.Voltagemustbe
within10%ofratingplate.Ifnot,contacttheinstallingelectricalcontractorandhavethevoltage
conditioncorrectedbeforecontinuingstart‐up.

10. Crankcaseheatersmustbeenergizedforatleasttwenty‐fourhourspriortostartingthe
compressors.Checktoseeifheatersareworking.

11. Attachservicegauges.Someunitsareequippedwithoptionalservicevalvesatvariouslocations.
Ensureallservicevalvesandpostvalvesarebackseated(fullyopen).

12. Rotationcheck.

Checkrotationofall3phasemotors.Motorswerecheckedforcorrectrotationatthefactory,if
rotationisincorrect,turnoffdisconnectswitchandreverseanytwopowerleadsleavingthe
disconnectswitch.Re‐checkrotation.
Caution:
ScrewandScrollcompressorsMUSTbecheckedforproperrotationatstartup.
Permanentdamagecanoccurifrotationisnotcorrect.


Scrollcompressorsrunningbackwardswilltypicallyhavelowheadpressure,highsuctionpressure
andareusuallynoisy.ScrewcompressorsMUSTbecheckedwithaphasemeterbeforestarting.If
rotationisincorrect,instantaneouspermanentdamagecanoccur.

ReciprocatingandTurbocorcentrifugalcompressorsdonotrequirerotationalchecks.

13. Atalltimesoftheyearunitsequippedwithwatercooledcondensersareshippedwithaglycol
solutioninthecondensertopreventfreezedamageduringshipping.Dependingontheapplication,
thecondensersmayhavetobeflushedpriortouse.Disposeoftheglycolasrequiredbylocal
authoritieshavingjurisdiction.Turnonthewatersupplyandfillthecondenser.Checkforwater
leaks.

14. Turnontheserviceswitch.Setcontrolstocallforcooling.Thesupplyfanwillstartasdescribedin
theunitfunction.Thecompressorsshouldnowbereadytostart.Condenserfanswillstartas
requiredwhencompressorsareoperating.Ifthecompressorisequippedwithanoillevelsight
glass,checktheoillevel.

15. Checktheamperagedrawofeachmotorandcompressor.Refertounitormotorratingplatefor
fullloadamps.Attheunit,checkandrecordthevoltagewhileitisrunning.For3phasepowerthe
phasetophasevoltageimbalanceshouldbelessthan2%.A2%voltageimbalancecancauseupto
a10%currentimbalancethatwilloverheatmotorwindings.



APD MANUAL
IOM-39 17 of 36 Aug 99 R1

Tocalculatevoltageimbalance(NEMAmethod)refertothefollowingexample:

Phasetophasevoltagereadings:  235V236V230V
TheaverageVoltagebetweenlegsis  (235+236+230)/3=233.7V
Highestvoltagedeviationfromaverageis: 233.7V–230V=3.7V
Voltageimbalancepercentage=HighestdeviationdividedbyaverageX100

3.7/233.7x100=1.6%Thisimbalanceislessthan2%andthereforeisOK

Ifvoltageimbalanceisgreaterthantwopercent(2%),turnoffmaindisconnectandcontactthe
installingelectricalcontractortohavethevoltageconditioncorrected.

16. Confirmfieldwiringvoltagedropislessthan10%whenequipmentisoperating.

17. Fortheunittooperateproperlyasystemairbalancemustbeperformedtoensurecorrectairflow.
Failuretodosocandamagetheequipmentand/orbuildingandcanbeacauseofpoorindoorair
quality.

18. Coilairbypassadjustment.
Formostpoolapplicationstherewillbeanairbypasssectionaroundtheevaporatorcoil.This
sectionallowsaportionofairtobypasstheevaporatorcoilallowingtheevaporatortohavethe
mostefficientmoistureremoval.Thebypassisfactorysettoadefaultvalueandmustbefield
adjustedtoensureproperoperation.Withthesystemrunningatfullloadconditions,install
refrigerationgauges.Adjustthebypassdampertomaintainasuctionpressurethatcorrespondsto
asaturatedsuctiontemperatureasspecifiedintheunitfunction(and/orthesubmittal),typicallya
saturatedsuctiontemperatureof40°Fto45°F(5°Cto7°C).Toomuchbypassairandthecoilsmay
freeze.Notenoughbypassair,andthecoilmaynotremoveenoughmoisturetosatisfythezone
conditions.

19. Dampersections:

a) Flatmixingdampers:
Boththefreshairandreturnairdampersarefullyopenwhenthedampersareata45°anglewhen
fullystroked.Thisprovidesoptimummixingoftheairstreamsforthisdamperarrangement.

b) Anglemixingdamper:
Anglemixingsectiondampersopentoanangleof90°whenfullystroked.Thisprovidesoptimum
mixingoftheairstreamsforthisdamperarrangement.

20. Allowsystemtooperateuntilstablerunningconditionshavebeenestablished.

21. Checkandrecordamperagedrawofeachmotorandcompressor.Refertounitlabelforrunning
fullloadampsofmotorsandcompressors.


APD MANUAL
IOM-39 18 of 36 Aug 99 R1
1 1/2" (40mm)
22. Measureandrecordthesuctionanddischargepressures.Oncompressorsequippedwithanoil
pump,measureandrecordnetoilpressure.(netoilpressureisoilpressureminussuction
pressure.).

Checkandrecordtheoilleveloncompressorsthatareequippedwithoillevelsightglasses.

23. Checksystemcharge:

Whenthermostaticexpansionvalves(TXvalves)areprovided,thechargecanbecheckedwiththe
liquidlinesightglass.Undernormaloperatingconditionsthesightglassisclearofbubbles.Refer
toChargingInstructions.

NOTE:Itispossibleforconditionsotherthanlowrefrigerantchargetocausethesightglassto
bubble.Bubblingmayoccurwhencondenserfanscycleson,superheatsettingistooloworfilter‐
drierispluggedetc.

TheTXvalvesuperheatwascheckedandadjustedatthefactorytomaintainasuperheatof18°F
(10°C)plusorminus3°F(2°C)measuredonthesuctionline10inches(250mm)fromthe
compressor.Thissettingrarelyrequiresreadjustment.Shouldadjustmentbenecessary,referto
theTXvalvemanufacturersrecommendations.
24. Condenserfanblades:Fanbladesmust
becorrectlypositionedwithintheorifice
forproperairflow.

25. Setallcontrolstothesettingsindicated
onthewiringdiagram.

26. Re‐installallaccesspanels.

27. Removeanypackingmaterialordebrisanddisposeappropriately.

APD MANUAL
IOM-39 19 of 36 Aug 99 R1
OPERATION
Warning:Thisunitisconnectedtohighvoltages.Electricalshockordeathcouldoccurif
instructionsarenotfollowed.Thisequipmentcontainsmovingpartsthatcanstart
unexpectedly.Injuryordeathcouldoccurifinstructionsarenotfollowed.Allwork
shouldbeperformedbyaqualifiedtechnician.Alwaysdisconnectandlockoutpower
beforeservicing.DONOTbypassanyinterlockorsafetyswitchesunderany
circumstances.



Warning:Propercommissioningandstart‐upoftheairhandlingsystemistheresponsibilityofthe
installingcontractor.Itisrecommendedthatanairbalancebecompletedbyacertified
airbalancingcontractortoinsuretheairvolumebeingdeliveredmatchestheunitrating
plate.Failuretoperformaproperairbalancecancauseinjuryordeath,damagetothe
equipment,propertydamage,systemoperationalproblems,orbeacauseofpoorair
quality.Moisturecarryovercanresultfromimproperairflow.


Thisunitmayincorporateoneormorefunctionsandavarietyofcontrolsandoptionstosuitindividual
requirements.AdescriptionoftheunitfunctionsandoptionsisshownontheElectricalDataSheetand
unitwiringdiagram.Carefullycheckyourwiringdiagramtoverifythatallremotecontrolsareproperly
locatedandcorrectlyfieldwired.

Dehumidificationsystemsfirstcooltheairwithanevaporatorcoiloperatingbelowthedewpoint
temperature,atwhichtimemoistureisremoved.Thecoolairisthenreheatedbacktotherequired
supplyairtemperature.Reheatisgenerallyaccomplishedusingasecond,parallel,internalcondensingcoil
toprovidethenecessaryamountofreheat.Insomecases,asecondaryheatsourcemaybeusedto
reheattheairi.e.electricorgasfiredheatexchanger.Condenserreheatsystemsmayemployeithera
switchedormodulatingcontrolsystem.Excessheatmayberemovedusingtheoutsidecondenser,and/or
apoolwaterheatexchanger,dependingonthesystemarrangement.

Someequipmentmaycontainprogrammableunitarycontrollersorprogrammablelogiccontrollers(PLC).
Additionalinformationcanbeobtainedfromthespecificprogrammablecontrolmanufacturer.Oftenthis
informationisavailablefromthecontrolmanufacturer’swebsite.

COOLINGCOMPONENTS

Refertothewiringdiagramandunitfunctionforspecificinformation.Standardpressurecontrolsettings
arefoundonpage34andthefollowingnotes.Applicationspecificcontrolsettingsarenotedonthewiring
diagramandintheunitfunction.

1. HermeticCompressors:

a. LowPressureControls:
Allcompressorshaveanauto‐resetlowpressurecontrolwithcontactsthatopenatlow

APD MANUAL
IOM-39 20 of 36 Aug 99 R1
pressureandclosewhenthepressureincreases.Seeunitfunctionforapplicationspecific
pressurecontrolsettings.

b. Highpressurecontrols:
c. Manualresetforaircooledcondensers,automaticresetforwatercooledcondensers.

d. OverheatandOverloadProtection:
e. Hermeticcompressorsaretypicallysuppliedwitheitherawindingthermostatorcurrent
sensingoverloaddevice.Thesearecapableofsensingmotoroverheatingcausedbya
shortageofgas,refrigerantsystemrestrictions,singlephasingorlockedrotorconditions.
Note:Windingthermostatscanstayopenforuptotwentyfourhoursundersome
conditions.


2. EngaIntercooler
TheEngineeredAirFlashIntercoolerisaheatexchanger
installedbetweentheTXvalveandthedistributortoreduce
flashgasattheTXvalveunderadverseoperatingconditions.



3. LowAmbientCompressorLock‐Out:
Thesecontrolswillpreventthecoolingsystemfromstarting
whentheambienttemperatureistoocoldandareprovided
asstandard.Thelowambientcontrolmaybepartofthe
systemcontrolleroraseparatedevice.

4. HeadPressureControl:
Headpressurecontrolsaredesignedtomaintainanadequateoperatingheadpressure,toallow
theTXvalveandothercomponentstoworkcorrectly.Lowheadpressurescancauseflashinginthe
sightglass,TXvalveunderfeedingandlowsystemcapacity.

EngineeredAirsystemsarecustombuiltandmayemployanyofseveraldifferentmethodsof
controllingheadpressure.CondenserFanCycling(CFC)headpressurecontrolswillcyclefansto
maintainproperheadpressureoncoolerdays.

Condenserfloodingheadpressurecontrolsareusedtocontroltheeffectivesurfaceareaofthe
condensersduringmodulatingreheatoperation.Thesesystemsdonotusepressureactuatedfan
cyclingcontrols.Condenserfansareeitherconstantrunorcycledbyambienttemperature.Refer
tothevalvemanufacturers’literatureforinformationregardingoperationofthesevalves.Referto
unitfunctionforadescriptionofsystemoperation.

5. PumpdownSystem(Optional):
Dependingonoptions,thecoolingsystemmayincludealiquidlinesolenoidforrefrigerantcontrol
andmanagement,thecontrolcircuitmaybewiredfor:

TX VALVE
UPFLOW DISTRIBUTOR
SIGHT GLASS
(OPTIONAL)
LIQUID OUT
LIQUID LINE
SIGHT GLASS
(OPTIONAL)
HOT GAS BYPASS
CONNECTION
(OPTIONAL)
LIQUID I N