SpacePak ESP-J Installation, Operation & Maintenance Manual
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SpacePak ESP-J Installation, Operation & Maintenance Manual

Central air conditioning 2 to 5 tons fan coil unit/air supply components
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MODEL
ESP-J & ESP-JV
INSTALLATION,
OPERATION
& MAINTENANCE
MANUAL
Central Air Conditioning Series
2 to 5 Tons
Fan Coil Unit/Air Supply
Components
SpacePak System Design........................................
Code Compliance.....................................................
Air Distribution Requirements...................................
Model Number Description.......................................
Air Distribution Components.....................................
High Altitude Guidelines............................................
Shipment of Unit.......................................................
Step 1: Locating The Unit.........................................
Step 2: Cutting Return Air Opening..........................
Step 4: Setting The Unit............................................
Step 9: Wiring The Unit..............................................
Layouts.................................................................
IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 (413) 564-5530/FAX (413) 564-5815
IN CANADA: 7555 TRANMERE DRIVE, MISSISSAUGA, ONTARIO, L5S 1L4 (905) 670-5888/FAX (905) 670-5782
Controls Overview................................................
2
System Commissioning.......................................
2
2
Charging Cooling Only Systems..........................
2
3-6
6
Before Each Cooling Season................................
6
If System Fails To Operate....................................
Troubleshooting Guide..........................................
Troubleshooting Flow Charts................................
7
Service/Troubleshooting Form..............................
10
Parts List...............................................................
10
11
WARRANTY INFORMATION.................................
12
13-17
13-17
17,18
19
20-24
ESPJ2-0323
45W30-WG1283
26-36
37
37
38
39
39
40, 41
42-45
46
47,48
49

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Summary of Contents for SpacePak ESP-J

  • Page 1: Table Of Contents

    ESPJ2-0323 45W30-WG1283 MODEL ESP-J & ESP-JV INSTALLATION, OPERATION & MAINTENANCE MANUAL Central Air Conditioning Series 2 to 5 Tons Fan Coil Unit/Air Supply Components SECTION 1: INTRODUCTION SECTION 3: START-UP & COMMISSIONING SpacePak System Design........Controls Overview..........26-36 Code Compliance.............

  • Page 2: Section 1: Introduction

    SpacePak is a hi-velocity central air conditioning system Protection Association 90A or 90B. which utilizes a conventional outdoor condensing unit matched with the indoor Model ESP-J fan coil unit to Do not begin the installation of the system without provide conditioned air through the specially-designed, performing a load calculation to determine heat gain, pre-fabricated, pre-insulated flexible duct system.
  • Page 3 Smart Seal assembly SECONDARY DRAIN PAN: Specifically sized for reference only. SpacePak horizontal fan coil units. Constructed of durable polyethylene. Fan coil unit sets directly on R6 SUPPLY TUBING (AC-ST6-100): Flexible, R6 insulated, top and can be installed with threaded rod.
  • Page 4 FIGURE 1.2: AIR DISTRIBUTION SYSTEM COMPONENTS RETURN AIR BOX (SPC-1D, AC-RBF-3, SPC-3D): R8 SUPPLY TUBING (AC-ST8-50): Flexible, R8 insulated, Each includes filter grill with metal frame, permanent 2" I.D. and 6-1/4" O.D. Each section is 50 feet long. filter, and 2 clamp bands. SPC-1D is for ESP-2430JV. AC- RBF-3 is for ESP-3642JV and SPC-3D is for ESP-4860JV.
  • Page 5 FIGURE 1.3: COMMON DUCTING LAYOUT. FOR REFERENCE ONLY. ALL SPACEPAK DUCTING RULES FOR SIDE BRANCHES, BULL HEAD TEES ETC.. SHOULD BE FOLLOWED...

  • Page 6: High Altitude Guidelines

    Installation of horizontally discharged terminators MINIMUM NO. OF is assisted with the SpacePak 90˚ wall elbow. Two excellent ALTITUDE OUTLETS PER TON spots for horizontal discharge are in the soffit area above 5000 - 6500' kitchen cabinets (see Figure 1.5) and in the top portion of...

  • Page 7: Section 2: System Installation

    When installing the unit above a finished ceiling or living such as a basement, closet or utility room (see dimen- space, install a secondary drain pan. Always follow local sions in Figures 2.2, 2.3 and 2.4). code requirements. FIGURE 2.1: MODEL ESP-J SPECIFICATIONS Recommended Connections Condensing Unit System Cond.
  • Page 8 FIGURE 2.3: VERTICAL UNIT DIMENSIONS AND CLEARANCES (Inches) FIGURE 2.4: CONNECTION LOCATIONS AND ASSEMBLED PLENUM ADAPTER DIMENSIONS FIGURE 2.5: TYPICAL UNIT INSTALLATION CLAMP BAND FLEXIBLE RETURN DUCT (90 BEND) SPACEPAK FAN COIL UNIT CLAMP BAND 48" MIN. SUPPLY AIR OUTLET PLATFORM (FIELD ERECTED...
  • Page 9 FIGURE 2.6: HORIZONTAL AIR FLOW UNIT INSTALLATION SUPPORT RETURN AIR BOX 90° 14 Ft. MAXIMUM FLEXIBLE RETURN DUCT 2 Ft. SUPPORT MAX. FAN COIL UNIT SUPPLY AIR 90° PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4) FIGURE 2.7: TYPICAL INSTALLATION WITHOUT DUCTED RETURN...

  • Page 10: Step 2: Cutting Return Air Opening

    #8 X 3/4 not install the return air box until the installation of the MOUNTING SCREWS (10 SUPPLIED) entire SpacePak system is completed, if you want to fit materials up through this hole. 10 INCH SQUARE SUPPLY AIR PLENUM ADAPTER ASSEMBLY KIT PART NO.

  • Page 11: Step 4: Setting The Unit

    Step 4: Setting the Unit Construct a platform for the fan coil unit, as shown in For locations where the fan coil unit will be suspended, Figure 2.12. The platform can be constructed of 2 x 4 suspend platform from overhead by 1/4" threaded rods. (minimum), 2 x 6, 2 x 8 and 2 x 10 lumber, as necessary to achieve proper pitch of 1/4"...

  • Page 12: Step 5: Connecting Refrigerant Lines

    SpacePak also recommends installing a sight the piping run. Proper line sizing is critical to the operation glass on the liquid line outside of the unit as an aid for of the system.

  • Page 13: Step 6: Installing The Condensate Trap & Line

    Keep all tees and elbows to a minimum to keep system pressure drop on larger layouts to a minimum. NOTICE: The following section provides with best general practices for installing SpacePak ductwork. For more details or specific duct configurations, please contact your local rep or info@spacepak.com...
  • Page 14 (see Figure 2.15). The result would be unacceptable noise. Push the free end of the sound attenuating tube through OPTION: Using a SpacePak Kwik Connect Wall the 4" hole until the two toggle springs on the room ter- Elbow (Model Number: AC-KCWE) addresses this minator snap into place.
  • Page 15 UL181 approved tape. fasteners one at a time such that each clip reaches the interior of the duct. Using the SpacePak pliers, snap the fasteners into place until they lock in place (see Figure FIGURE 2.20: KWIK-CONNECT INSTALLATION 2.23).
  • Page 16 FIGURE 2.23: PLENUM TAKE-OFF FASTENER INSTALLATION GASKET GASKET PLENUM PLENUM TAKE-OFF PLENUM TAKE-OFF PLENUM FASTENER FASTENER 1. HAND INSERT FASTENER INTO PLENUM TAKE-OFF 2. WITH PLIERS, SNAP FASTENER INTO PLACE UNTIL IT LOCKS IN PLACE In accordance with your calculations as to requirements Remove the grill and the filter from the grill frame.

  • Page 17: Step 8: Retrofit To B & C Series Units

    9” RND w/40% of Total Outlets 7” RND w/60% of Total Outlets Handler DESIGN RULES FOR RETRO- FITTING “B&C” SERIES SPACEPAK EQUIPMENT TO NEWER (D,E,F,G,J ) SERIES EQUIPMENT A: No outlets in the first 18” of straight pipe coming off the Air Handler B: Minimum distance between outlets is 6”...
  • Page 18 9” Tee Handler C & D DESIGN RULES FOR RETRO- 7” RND w/40% or 50 % of Total Outlets FITTING “B&C” SERIES SPACEPAK A & B EQUIPMENT TO NEWER (D,E,F,G,J) SERIES EQUIPMENT 7” 90˚ A: Minimum distance from the air handler outlet to first tee or elbow is 18”...

  • Page 19: Step 9: Wiring The Unit

    Locate the room thermostat on a wall near the return air box. Install the selected thermostat per the thermostat manufacturer's installation instructions. Ensure the proper wiring from the thermostat to the SpacePak air handler by following the air handler diagrams found in this manual.

  • Page 20: Layouts

    FIGURE 2.33: MODEL ESP-J 230V STANDARD WIRING DIAGRAM* ESP & WCSP 120V/230V BOILER/PUMP CONTROL ALL TEMP SENSORS 10K NTC LEAVING AIR 120VAC FIELD CONVERSION SENSOR EXTERNAL COIL (IF INSTALLED) SENSOR PRIMARY COIL SENSOR PRESSURE 240V B- A+ 120V L1 PRIMARY 120VAC...
  • Page 21 FIGURE 2.34: SINGLE STAGE AIR CONDITIONING ONLY WIRING DIAGRAM ESP 120V/230V SINGLE STAGE REFRIGERANT CONDENSER ONLY TEMPERATURE...
  • Page 22 FIGURE 2.35: SINGLE STAGE AIR CONDITIONING WITH HW COIL WIRING DIAGRAM ESP 120V/230V SINGLE STAGE REFRIGERANT CONDENSER WITH HW COIL/BOILER OR ELECTRIC HEAT ELECTRIC BOILER/PUMP HEAT CONTROL TEMPERATURE ELECTRIC BOILER/PUMP HEAT CONTROL...
  • Page 23 FIGURE 2.36: TWO STAGE HEAT PUMP/AC WIRING DIAGRAM ESP 120V/230V TWO STAGE HEAT PUMP REFRIGERANT CONDENSER TEMPERATURE...
  • Page 24 FIGURE 2.37: TWO STAGE HEAT PUMP/AC WITH BACKUP BOILER HEAT WIRING DIAGRAM ESP 120V/230V TWO STAGE REFRIGERANT CONDENSER WITH HW COIL/BOILER OR ELECTRIC BACKUP HEAT BOILER/PUMP CONTROL TEMPERATURE BOILER/PUMP CONTROL...
  • Page 25 Integral Air Handler Control The SpacePak ESP and WCSP air handlers now feature All delivered airflow and static pressure, for each a sophisticated control platform that has the ability to application, should be verified upon installation with control fan speed by measuring static pressure and...

  • Page 26: Section 3: Start-Up & Commissioning

    SECTION 3: START-UP & COMMISSIONING Controls Overview/Features/Setpoints J+ Control Board Navigation *IMPORTANT* When making selections the user MUST press the "SEL" key to save the desired selection. If the "SEL" key is not pressed the control will revert to the previous setpoint/selection.
  • Page 27 RUN SCREEN Line 1: FAN, and Humidifier are running Line 2: Humidifier [HSTAT] HVAC input is energized There are 5 run screens that show the current status of the unit. Pressing the UP or DOWN buttons will cycle through the 5 screens. F A N H S T A T Run Screen #1.
  • Page 28 C O I L O P E N C O I L N O N E Run Screen #4. L A T ° F F A N S P E E D 1 0 0 Run Screen #5. Line 1 shows the Model and Size. Line 2 shows the Unit type: Reverse Cycle Chiller, Heat Pump, Cooling or Heating mode only, as well as the Reversing valve setting, and the secondary heating water...
  • Page 29 The following menu trees are accessible within the advanced control. They can be accessed by holding the "ESC" key down for 3 seconds. Within these menu trees are configurable settings for each application and unit type. Please refer to the proper menu tree per the firmware version on the control board prior to making any changes or adjustments to the unit configuration.
  • Page 30 Firmware versions 1.4 and lower (upon startup of the unit, verify proper firmware version STANDBY before following this menu tree) 3 Sec “ESC” KEY HOLD DOWN TIME MODEL UNIT SETTINGS SETUP SYSTEM FAN SETTINGS 2430JH, 2430JV,3642JH UNIT SIZE 3642JV,4860JH, 4860JV UNIT TYPE ESP: HP OR AC DEFAULTS...
  • Page 31 Firmware versions 1.5 and higher STANDBY (upon startup of the unit, verify proper firmware version before following this menu tree) 3 Sec “ESC” KEY HOLD DOWN TIME SETUP UNIT SETTINGS MODEL SYSTEM 2430JH, 2430JV,3642JH FAN SETTINGS UNIT SIZE 3642JV,4860JH, 4860JV ESP: HP OR AC UNIT TYPE WCS: R CC, AC, O R HEAT...
  • Page 32 The Aux2 and 3 terminals are designed to work 1.1 MODEL: This menu will allow you to select the with the Spacepak Air to Water Heat pump family model of the unit: ESP or WCSP. of products. Aux2 will be wired to the “remote 1.2 UNIT SIZE: There are 6 unit sizes options:...
  • Page 33 1.8. Anti-Frost protection temperature setting: The default speed value is 50%. Line 1 displays the units, and line 2 shows the real time value of The Anti-Frost Protection Temperature setting the parameters. Selecting Y1% will set the cursor [AFST TEMP] controls the integrated Anti-frost at line 2 indicating real time adjustment is active.
  • Page 34 2.2 FAN START TEMP: The temperature of the SYSTEM MENU heating/cooling coils is constantly being The System menu consists of two items; Defaults and Cal monitored. When a call for heating or cooling is pressure. received the fan will not start until the coil is at the SYSTEM DEFAULTS appropriate temperature (note: for firmware...
  • Page 35 FAULTS AND WARNINGS: above the setpoint. For units with firmware 1.5 or The integrated control board is equipped to identify com- greater, the unit will reset after the coil 1 temperature is mon faults and potential warnings during the operation 20°...
  • Page 36 ADDITIONAL SUPPLEMENTARY FEATURES OF THE J+ CONTROL The J+ control has 3 inputs that can be used to interface with supplemental equipment. These inputs are enabled when 24VAC is applied. HVAC Outputs HVAC Inputs LCD Buttons Temperature Pressure 24VAC T-Stat Inputs Energy Recovery HP Defrost An Energy Recovery Ventilator can use the [ERV] input to have...

  • Page 37: System Commissioning

    CFM requirements, please refer to the troubleshooting guide for "Improper airflow". Or reach Releasing refrigerant gas into the atmo- out to technicalservice@spacepak.com for toubleshoot- sphere is a criminal offense. ing help. DO NOT TRY TO CHARGE A SYSTEM WITH- OUT PROPER AIRFLOW BEING ESTABLISHED.

  • Page 38: Factors Affecting The Balance Of The System

    1.65 tem performance. It is highly recommended that the ad- (1) + (1) .35 or (2) .5 + (1) .35 justment factors outlined in the SpacePak Application 1.70 (2) .15 Manual are accounted for prior to any installation.

  • Page 39: Section 4: Maintenance & Troubleshooting

    3. Contact SpacePak technical support. BEFORE EACH COOLING SEASON 1. Check and clean air filter. The SpacePak air filter is perma- nent type. If the filter is the SpacePak filter, remove and clean thoroughly with soap solution and water. If the filter is a field supplied (non-SpacePak filter) follow that manufac- turers instructions on how to maintain.

  • Page 40: Troubleshooting Guide

    TROUBLESHOOTING GUIDE Faults displayed on screen Display Unit Type Description Possible Causes Solutions Clogged drain causing Identify location of clog and clear clog The primary drain pan float float switch to trip switch has faulted. A Y call to Broken float switch Inspect for damage.
  • Page 41 Remove and Inspect Blower Assembly. Remove and foreight matter and retest fan vibration. Unbalanced * The table above explains the most common symptoms and solutions for SpacePak troubleshooting. Please reach out to technicalservice@spacepak.com if the problem is not resolved using this table.

  • Page 42: Troubleshooting Flow Charts

    TROUBLESHOOTING FLOW CHARTS No Thermostat Call Displayed on Board Proper 240v incoming Turn on Main Is Main Breaker (115 if converted) across Breaker L1 and L2? Is line voltage on Check for loose/ Check for loose Is problem still Is problem still primary side (see damaged wires wiring, repair as...
  • Page 43 Coil not at proper temps See "No thermostat call Is there a demand displayed on from the thermostat? board" Refer to Fault/ Warning table. Is external device Correct as instructed (condenser/boiler/heat pump etc...) operating? Is J+ sending Any faults signal to external displayed? device? Is problem still...
  • Page 44 Correct as needed Problem still there? Problem still there? Using wiring diagram. Verify all wire harnesses are Problem still properly secured there? and properly manufactured. Repair/replace as needed Call SpacePak tech Unit Operating support...
  • Page 45 10k OHM TEMP SENSOR RESISTANCE TABLE (LAT Sensor and Coil Sensor) °C °F 336,098 242,427 176,803 130,306 97,006 72,911 55,307 42,317 32,651 25,395 19,903 15,714 12,493 10,000 8,056 6,530 5,325 4,367 3,601 2,985 2,487 2,082 1,752 1,480 1,256 1,076...

  • Page 46: Service/Troubleshooting Form

    Temp: °F; Superheat: °F Equipment Data: Approximate time running before taking readings: Hrs. SPACEPAK Model # ESP / WCSP - Did you adjust the TXV? (Y/N); (If yes, explain): SPACEPAK Serial # SPACEPAK Date of Installation: Cond Unit Mfr:...

  • Page 47: Parts List

    FIGURE 4.1: MODEL ESP-J GENERAL ASSEMBLY DETAIL OF INTERNAL CONTROL BOX WITH COVER REMOVED SPL-WG1292-01 = NOT SHOWN Replacement Parts - Horizontal Fan Coil Units Item Part Description Unit Size Part Number WCSP 2430J 45W06RWG0220-22 Primary Drain Pan 3642J 45W06RWG0220-23...
  • Page 48 DETAIL OF INTERNAL CONTROL BOX WITH COVER REMOVED = NOT SHOWN SPL-WG1294-01 Replacement Parts - Vertical Fan Coil Units Item Part Description Unit Size Part Number WCSP 2430J 45455RWG1012-02 Primary Drain Pan Assembly 3642J 45455RWG1012-03 4860J 45455RWG1012-04 2430J 45469RWG1013-02 R410A Coil Assembly 3642J 45469RWG1013-03 4860J...

  • Page 49: Warranty Information

    (3) below). If any parts should prove defective due to improper workmanship and/or material for a period of one (1) year from the date of installation, SpacePak will replace any defective part without charge for that part. Replacement parts are warranted for the remainder of the original 1-year warranty period. Parts used as replacement may be of like kind and quality and may be new or remanufactured.
  • Page 50 The following items apply to each Limited Warranty offered by SpacePak. 4) NO LABOR. Each Limited Warranty offered by SpacePak does NOT include labor or any other costs incurred for service, maintenance, repair, removing, replacing, installing, complying with local building and electric codes, shipping or handling, or replacement of the System/Products, compressors or any other parts.
  • Page 52 IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 (413) 564-5530/FAX (413) 564-5815 IN CANADA: 7555 TRANMERE DRIVE, MISSISSAUGA, ONTARIO, L5S 1L4 (905) 670-5888/FAX (905) 670-5782...

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