Space Pak ESP-K Series Installation, Operation & Maintenance Manual

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MODEL

ESP-K & ESP-KV

INSTALLATION,

OPERATION

& MAINTENANCE

MANUAL

Central Air Conditioning Series

2 to 5 Tons

Fan Coil Unit/Air Supply

Components

SECTION 1: INTRODUCTION

SpacePak System Design............................................ 2

Code Compliance......................................................... 2

Technical Service Guide......................................3,4

Model Number Description.............................................. 5

Air Distribution Requirements...................................... 5

Air Distribution Components........................................ 6-7

Plenum Duct...................................................................8

Shipment of Unit ..................................................... 8

SECTION 2: SYSTEM INSTALLATION

Step 1: Locating The Unit............................................10

Step 2: Cutting Return Air Opening.............................14

Step 3: Attaching Supply Air Plenum Adapter..............14

Step 4: Setting The Unit..............................................15

Step 5: Connecting Refrigerant Lines........................ 16

Step 6: Installing The Condensate Trap & Line..........17

Step 7: Installing Air Distribution Components.......17-21

Step 8: Retrofit to B & C Series Units...................21-23

Step 9: Wiring The Unit........................................ 23,24

IN UNITED STATES: 260 NORTH ELM ST. WESTFIELD, MA 01085 (413) 564-5530

IN CANADA: 7555 TRANMERE DRIVE, MISSISSAUGA, ONTARIO, L5S 1L4 (905) 670-5888

SECTION 3: START-UP & COMMISSIONING

Controls Overview.................................................. 26-36

System Commissioning.............................................. 37

Factors Affecting the Balance of the System............ 38

SECTION 4: MAINTENANCE & TROUBLESHOOTING

Before Each Cooling Season..................................... 39

If System Fails To Operate........................................... 39

Troubleshooting Guide............................................ 40, 41

Troubleshooting Flow Charts................................. 42-44

Service/Troubleshooting Form...................................... 46

Parts List............................................................. 47-50

PRODUCT REGISTRATION.................................. 51

WARRANTY INFORMATION................................. 52

ESPK2-0625

W30-WG1708-01

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Summary of Contents for Space Pak ESP-K Series

Page 1 ESPK2-0625 W30-WG1708-01 MODEL ESP-K & ESP-KV 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..........2 Controls Overview..........26-36 Code Compliance............2 System Commissioning..........
Page 2 SECTION 1: INTRODUCTION The following terms are used throughout this manual to bring The appliance is not to be used by persons attention to the presence of potential hazards or to important (including children) with reduced physical, sensory or mental information concerning the product: capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
Page 3 Technical Service Guidelines Prior to beginning work on systems containing FLAMMABLE Checks to Electrical Devices REFRIGERANTS, safety checks are necessary to ensure that the Repair and maintenance to electrical components shall include initial risk of ignition is minimized. safety checks and component inspection procedures. If a fault exists Before conducting any repairs or maintenance activities, review that could compromise safety, then no electrical supply shall be con- nected to the circuit until it is satisfactorily dealt with.
Page 4 Charging Procedures Recovery In addition to conventional charging procedures, the following When removing refrigerant from a system, either for servicing or requirements shall be followed. decommissioning, it is recommended good practice that all refrig- • Ensure that contamination of different refrigerants does not occur erants are removed safely.
Page 5 ESP-K - MODEL NUMBER DESCRIPTION 1,2,3, - Unit Type [UT] 9 - Cabinet Type [CT] ESP - Vapor Cycle Fan Coil Unit H - Horizontal V - Vertical 4,5,6,7 - Capacity [CA] 2430 - 24,000 to 30,000 BTU/Hr. (2-2 tons) 10 - Refrigerant Type [RT] [7.03 to 8.79 kW] Z - Other...
Page 6 FIGURE 1.1: AIR DISTRIBUTION SYSTEM COMPONENTS RETURN AIR BOX (BM-9149, AC-RBF-3, BM-9169): Each INSTALLATION KITS: Contains a specified amount includes filter grill with metal frame, permanent of sound attenuating tubes, kwik-connects, terminator plates filter, and 2 clamp bands. BM-9149 is for ESP-2430K. AC- (incl.
Page 7 FIGURE 1.2: AIR DISTRIBUTION SYSTEM COMPONENTS RETURN AIR BOX (SPC-1D, AC-RBF-3, SPC-3D): Each R6 SUPPLY TUBING (AC-ST6-75): Flexible, R6 insulated, 2 includes filter grill with metal frame, permanent in/ 51 mm I.D. and 5.38 in/ 137 mm O.D. Each section is 75 filter, and 2 clamp bands.
Page 8 Plenum Duct The plenum duct can be run in practically any location For systems designed with a bullhead tee installed as on Unit accessible for the attachment of the supply tubing (see No. 1 (Figure 1.4), the best results are obtained if not more than 60% of the total number of system outlets are attached to any suggested layouts in Figure 1.3).
Page 9 FIGURE 1.4: ESP-3642/4860 INSTALLATIONS FIGURE 1.5: TERMINATOR IN SOFFIT AREA UNIT NO. 1 FAN COIL UNIT NO MORE THAN ROOM MINIMUM 60% OF CAPACITY TERMINATOR 18"(460mm) ON ONE SIDE FIGURE 1.6: TERMINATOR IN CLOSET TOP AREA UNIT NO. 2 FAN COIL UNIT MINIMUM 18"(460mm) 30% MAX.
Page 10 SECTION 2: SYSTEM INSTALLATION When selecting a location, consider the location of the unit in NOTICE: Before proceeding with the installation, we relation to the return air box or filter box as shown in Figure recommend reading through this section of the manual for an overall understanding of the air conditioning fan coil unit and 2.5.
Page 11 FIGURE 2.3: UNIT DIMENSIONS AND CLEARANCES - Inches [mm] "A" "C" "B" " " " 3/8 LIQUID LINE 29 3 " SHRADER VALVE 7/8 SUCTION LINE ELECTRICAL ACCESS "A" PORTS "D" " " " " PRIMARY DRAIN " SECONDARY DRAIN Model 2430K 24 1/4”...
Page 12 FIGURE 2.4: VERTICAL UNIT DIMENSIONS AND CLEARANCES - Inches [mm] " 230V SUPPLY " LOW VOLTAGE " 3 15 " SUPPLY AIR OPENING "D" "C" " " 12 MIN CLEARANCE " 38 MIN CLEARANCE " " 16 1 " " Model 2430KV 24”...
Page 13 FIGURE 2.6: HORIZONTAL AIR FLOW UNIT INSTALLATION SUPPORT RETURN AIR BOX 90° 10' (3.05m) MAXIMUM FLEXIBLE 14 Ft. MAXIMUM FLEXIBLE RETURN DUCT RETURN DUCT 24" (610mm) SUPPORT MAX. MAX. FAN COIL UNIT SUPPLY AIR 90° PLATFORM (FIELD ERECTED AS SHOWN IN STEP 4) FIGURE 2.7: TYPICAL INSTALLATION WITHOUT DUCTED RETURN...
Page 14 Step 2: Cutting Return Air Opening Select exact location for return air box. Avoid installing box in FIGURE 2.9 dining room, living room, kitchen, etc., unless return air duct can be installed with at least two 90° bends (accomplished by splicing two return air ducts together.) For attic installations to raise fan coil unit up through opening, cut return air opening 14.5 in/ 369 mm wide by the "A"...
Page 15 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 in per foot/ 20mm per NOTICE: Allow room on sides for servicing.
Page 16 -RISK OF FIRE FLAMMABLE REFRIGERANT USED. TO BE REPAIRED ONLY BY TRAINED SERVICE PERSONNEL. DO NOT PUNCTURE REFRIGERANT TUBING. DISPOSE OF PROPERLY IN ACCORDANCE WITH FEDERAL and LOCAL REGULATIONS Step 5: Connecting Refrigerant Lines NOTICE: The Refrigerant Lines must be routed in a manner that they are never disturbed or displaced during normal Connect refrigerant lines from the outdoor condensing unit to unit operation.
Page 17 Step 6: Installing the Condensate Trap & Line NOTICE: It is a requirement of the International NOTICE: The secondary drain connection requires Mechanical Code (307.2.3) to install a secondary field supplied components to complete installation. drain or an auxiliary drain pan where damage to Follow local code requirements.
Page 18 FIGURE 2.15: INCORRECT TUBING INSTALLATION FIGURE 2.17: TERMINATOR MEASUREMENTS SOUND 4" DIA. ATTENUATING [102 mm] TUBE 5" [127mm] DRY WALL OR PLASTER 5" [127 mm] Assemble spring clips to terminator plate with screws THIS RADIUS provided in installation kit. Tighten clips until they are TOO SHORT close to the thickness of the material they are being mounted to.
Page 19 To cut a hole in the plenum, refer to duct installation Supply Tubing Installation instructions supplied with fan coil unit. Sheet metal duct Kwik-connects and balancing orifices are provided in the Instal- requires a 2-1/16" hole. lation Kits. Plenum take-offs, gaskets and fasteners are sup- plied in the separate plenum take-off kit.
Page 20 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 for the air filter into the frame and replace the grill.
Page 21 SHUT-OFF Step 8: B & C Series Unit Retrofits For retrofitting an ESP-K series unit to an existing ESP-B or C or field supplied 9 in/ 229 mm round duct. The return duct and series, some modifications will need to be made to the current return grille will also have to be replaced with the proper parts system.
Page 22 FIGURE 2.31: STRAIGHT DUCT OR SHOTGUN LAYOUT A: No outlets in the rst 18” [457 mm] of straight pipe coming o the Air Handler B: Minimum distance between outlets is 6” [153 mm] on center C: Minimum distance when placing an outlet from end cap is 12” [305 mm] D: NEVER place an outlet in the End Cap FIGURE 2.32: HORSESHOE LAYOUT A: Minimum distance from the air handler outlet to ﬁrst tee or elbow is 18”...
Page 23 FIGURE 2.33: SIDE BRANCH A: Minimum distance from the air handler outlet to ﬁrst tee or elbow is 18” [457 mm] B: No outlets in the ﬁrst 18” [457 mm] of straight pipe oﬀ of the air handler C: Minimum distance of straight pipe a er any tee or elbow is 18” [457 mm] D: Minimum distance when placing outlet a er any tee or elbow is 18”...
Page 24 FIGURE 2.34: MODEL ESP-K 230V STANDARD WIRING DIAGRAM*...
Page 25 *Only zoning devices that are expressly marked as Compatible All delivered airflow and static pressure, for each application, with SpacePak ESP-K Series air handlers, and installed strictly should be verified upon installation with calibrated equipment according to the Installation & Operation Manual may be used to ensure proper system operation and for troubleshooting in this system.
Page 26 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 F A N SYSTEM MENU. The System menu consists of two items; Defaults and Cal pressure. F A N The System menu consists of two items; Defaults and Cal pressure. SYSTEM DEFAULTS SYSTEM DEFAULTS The DEFAULTS menu allows all settings to be returned to factory default values indicated in Defaults Section. Line 1: FAN, and Humidifier are running RUN SCREEN UNIT MODEL and UNIT SIZE are not changed when loading factory defaults.
Page 28 C O I L 7 4 ° F C O I L 7 4 ° F C O I L 8 0 ° F C O I L 8 0 ° F Note: If the Secondary Hot Water Coil [SEC HW COIL] is disabled, line 2 will be blank. Note: If the Secondary Hot Water Coil [SEC HW COIL] is disabled, line 2 will be blank.
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 SPACEPAK A2L LEAK LOGIC START Rev 1.0 11/04/2024 REFRIGERANT LEAK: A2L RELAY OPEN CONTACTS? BLOWER SPEED 100% DISPLAY WARNING FAULT RELAY ON LEAK DETECTED RELAYS OFF: R,O/B, Y1,Y2,W1,W2, AUX1,AUX2,AUX3,HMDFR A2L RELAY OPEN CONTACTS? START 5 MIN BLOWER OFF DELAY TIMER OFF TIME DELAY COMPLETE DISPLAY...
Page 31 MENU TREE SPACEPAK K REV 1.4 STANDBY 3 Sec “ESC” KEY HOLD DOWN TIME SETUP UNIT SETTINGS MODEL SYSTEM FAN SETTINGS 2430JH, 2430JV,3642JH UNIT SIZE 3642JV,4860JH, 4860JV DISPLAY OPTIONS ESP: HP OR AC UNIT TYPE WCS: RCC, AC, OR HEAT DEFAULTS O [COOLING] REVERSE VALVE...
Page 32 UNIT TYPE The Reversing Valve [REVERSE VALVE] can be set to O [energized in co Escape key, used to exit menus and to undo changes. HEAT REVERSE VALVE Selection key, used to select features and to save changes. Commissioning and Adjusting Paramaters Menu navigation is accomplished by using the buttons located to the right side of the J+ control board.
Page 33 AUX 1 HEAT COOL HEAT-COOL 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 parameters. 1.7 FAN: The fan can be run at either a constant speed or a constant static pressure. The Anti-Frost Protection Temperature setting [AFST Selecting Y1% will set the cursor at line 2 indicating TEMP] controls the integrated Anti-frost feature.
Page 34 HUM: ST PRESS HUM SP PRES time to get to the target temperature. 0.39 ERV: ST PRESS ERV SP PRES The FAN OFF DELAY is always used to allow the fan to optionally run for 0.39 satisfied allowing time to offload the coil of any excess heat that may st DFS: ST PRESS HRV SP PRES...
Page 35 LOW PRESS FAULT- The pressure transducer (located on FAULTS AND WARNINGS: C O O L I N G The integrated control board is equipped to identify common the control board) is reading less than 0.1” W.C./ 25 Pa when faults and potential warnings during the operation of the air S H O R T E D C O I L 1 the fan is running.
Page 36 ADDITIONAL SUPPLEMENTARY FEATURES OF THE CONTROL The 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 Leak Detection Energy Recovery HP Defrost An Energy Recovery Ventilator can use the [ERV] input to have the...
Page 37 SYSTEM COMMISSIONING 4. For outdoor unit start-up, follow manufacturer’s instruc- 1. Although delivered static pressure is measured with the inte- tions. grated control board, it is important to verify an accurate read- ing, and within acceptable limits (minimum 1.2" W.C./ 299 Pa 5.
Page 38 FACTORS AFFECTING THE BALANCE OF THE SYSTEM Room Terminators (Outlets): Based on the equipment selected, determine the recommended number of fully open outlets from Figure 3.1. FIGURE 3.1 RECOMMENDED OUTLETS AND CFM/ m³/hr Model Size Nominal Recommend- Tonnage ed CFM/ m³/ Number of Total Total...
Page 39 SECTION 4: MAINTENANCE & TROUBLESHOOTING The SpacePak system has been designed to provide years of IF SYSTEM FAILS TO OPERATE trouble-free performance in normal installations. Examination by the 1. Refer to the troubleshooting guide in this manual. homeowner at the beginning of each cooling season, and in mid- season should assure continued, good performance.
Page 40 TROUBLESHOOTING GUIDE Faults displayed on screen Display Description Possible Causes Solutions Clogged drain causing float The primary drain pan float switch Identify location of clog and clear clog switch to trip has faulted. A Y call to the outdoor Broken float switch Inspect for damage.
Page 41 Project Complaints/Conditions* Problem Possible Cause Corrective Actions Check for refrigerant leaks in all refrigerant components. Repair leaks (as needed) per standard refriger- Refrigerant Leak ation practices Check for proper refrigerant charge. Charge to proper subcooling according to condenser manufacturers Improper charge instructions Evaporator coil dirty Check for a dirty evaporator coil.
Page 42 TROUBLESHOOTING FLOW CHARTS The REFRIGERANT LEAK message indicates that a significant amount Therefore, to clear the REFRIGERANT LEAK fault, (after the condition of refrigerant vapor has been detected inside the air handler. Once the has been corrected). With the unit powered and the REFRIGERANT vapor has been dispersed, the sensor will self reset, and the K Series LEAK message visible, press and hold the SEL button for three sec- control will maintain the blower operation for an additional five minutes,...
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 K sending Any faults signal to external displayed? device? Is problem still...
Page 44 Improper voltage Verify 115v conversion was Is problem still done properly per 115VAC? 115vac there? instructions sheet. 240VAC? Correct/repair as needed 240vac Check for loose Main Circuit connections in break on? wiring/repair as needed Problem still there? Turn on main circuit breaker Verify proper point to point wiring per...
Page 45 Refrigerant Leak Detector behavior and troubleshooting: All information below applies to both the R32 sensor and the R454B sensor. LED Indicator codes Cause Action Steady Green Warmup at power on None, this is normal behavior at startup Flashing Green Normal operation None Steady Yellow Power up Self Test fail...
Page 46 Service / Troubleshooting FORM “1A” Customer / Dealer Data: Refrigeration-side Data: Name: Line sizes: Liquid Suction Address: Total equivalent length of lines: ft/ m; Vertical Rise: ft/ m @ Condensing Unit: Liquid: psi/ kPa; Temp: °F /°C; Subcool: °F /°C Tel (day) (eve) Suction:...
Page 47 FIGURE 4.1: MODEL ESP-K GENERAL ASSEMBLY L BOX * NOT SHOWN SPL-WG1711_A DETAIL OF INTERNAL CONTROL BOX WITH COVER REMOVED...
Page 48 Replacement Parts - Horizontal Fan Coil Units Item Part Description Unit Size Part Number 2430 45W06RWG0220-22 Primary Drain Pan 3642 45W06RWG0220-23 4860 45W06RWG0220-24 2430 45469RWG1270-02 Refrigerant Coil Assembly 3642 45469RWG1270-03 4860 45469RWG1270-04 2430 45W28RWG0641-02 Thermal Expansion Valve, Chatleff Connection 3642 45W28RWG0641-03 4860 45W28RWG0641-04...
Page 49 FIGURE 4.2: MODEL ESP-KV GENERAL ASSEMBLY TAIL OF INTERNAL CONTROL BOX TH COVER REMOVED SPL-WG1712_A * NOT SHOWN DETAIL OF INTERNAL CONTROL BOX WITH COVER REMOVED...
Page 50 Replacement Parts - Vertical Fan Coil Units Item Part Description Unit Size Part Number 2430 45455RWG1012-02 Primary Drain Pan Assembly 3642 45455RWG1012-03 4860 45455RWG1012-04 2430 45469-WG1696-02 Refrigerant Coil Assembly 3642 45469-WG1696-03 4860 45469-WG1696-04 2430 45W28RWG0641-02 Thermal Expansion Valve, Chatleff Connection 3642 45W28RWG0641-03 4860...
Page 51 IMPORTANT NOTICE PRODUCT REGISTRATION & EXTENDED WARRANTY Extended Warranty Requirements • Project/Equipment Registration • To visit the Product Registration Page, click or scan the QR code. Check our Contractor Locator • Local Leads • Listed on SpacePak Website • Sales & Marketing Support •...
Page 52 LIMITED WARRANTY STATEMENT SpacePak Small Duct High Velocity Air Handlers and Hydronic Fan Coils Subject to the terms and conditions of this Limited Warranty Statement (the “Limited Warranty”), SpacePak warrants to the original purchaser of the Small Duct High Velocity Air Handlers and hydronic fan coils that: 1) The parts are warranted for a period of one (1) year to the original owner of the System (as such term is defined in part (3) below).

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