Economizer Damper and Hood* Installation for 15,20, and 25 Ton

Economizer Damper and Hood* Installation for 15,20, and 25 Ton
44-320-2 (1294)
Economizer Damper and Hood* Installation
for 15,20, and 25 Ton Rooftop Units
-
This instruction provides the necessary information to
properly field-install economizer dampers and hood
assembly on 15, 20, and 25 ton single package rooftop
unit,
The damper accessory provides the return air and
outdoor air dampers and actuator for economizer
operations. Contained m this kit are all rain hood
components
KitIncludes
Box #
1
1
1
1
2
2
1
Item#
1
2
3
4
5
6
7
Description
BottomTrack
Top Flange
ReturnAir(RA)Damper
ReturnAir/Outdcmr
Air(RNOA)Divider
OutdoorAir(OA)DamperwithActuator
DamperExtension(20and25TonUnits)
LinkageRod
Box #
3
3
3
3
3
3
1
3
Item#
8
9
10
11
12
13
14
Description
EconomizerHoodRightSidePanel
LowerFilterBracket
Economizer
HoodLeftSidePanel
EconomizerHoodMiddleSection
EconomizerHoodTop
EconomizerFilters
ElectronicsSub-Package
Bagof Screws
NOTE: To aasa installation,read all instructionsprior to assemblingeconomizer kit.
-
@ 1994 Johnson Controls, inc.
Patt No, 44-3202 Rev, —12-19-94
Patent Panding
●
1
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TOOISRequired
T plcal Panel Latch
e+
5/16inch hex socket driver
7/16 inch hex socket driver
3/8 inch hex socket driver
drill, for self drilling screws (recommend cordless)
socket drive extension
hammer
awl
*
CAUTION: When installing dampers, use
care to avoid damage to filters or
coils located in the adjacent
compaflment.
i
7/16 inch Hex Head
Screw
Access Panel
Access Panel
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Damper Assembly Procedures
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1,
1
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5/16 inch Hex Head
Screw
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Figure 3: Panel latch
1. Remove the three access panels (two OA and one
RA shown in Figure 1) by using a 7/16 inch hex
socket to loosen the screws securing the rotating
latches and a 5/16 inch hex socket to remove the
four screws on the bottom of each panel.
On 15 and 20 ton units, also remove the filter
access panel.
Note: Retain the “O” rings which provide the seal
between the panel and unit bottom.
A
Compartment
WARNING: If the return air duct cover has
been removed, install a covering
over the open hole to prevent
personal injury or equipment
damage.
Figure 1: Rooftop Unit
2.
Remove the support brackets on 20 and 25 ton
rooftop units:
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Figure4: Removing Support Bracket
Figure 2: InstalledComponents
2
●
Use a 5/16 Inch hex socket to remove the top
screws securing the support bracket located
between the return air and outdoor air
compartments.
●
Use a 5/16 Inch hex socket to remove the top
screws securing the corner support bracket.
●
Use a 3/8 inch hex socket to remove the two
inside top and bottom screws. Save the
screws and bracket for installation later.
A
CAUTION: Lift the roof when removing the
support bracket to prevent
tearing the roof seal.
.“
4.
Remove the RA damper and the top flange from
their packing materials.
I
I
/
..
,/ “
Use the screws previously removed to secure
the bottom track to the drip and bottom pan
flange,
Figure7: InstallingTop Flange
/.’
5.
Install the RA damper:
●
Inside the top IIP,align the holes of the top
flange with the holes in the lip.
●
Use the self drilling screws provided to secure
the top flange to the hp. Install the screws
from outside the unit as shown in Figure 7.
Linkage Arm with Swwel Ball Joints
I
Figure 5: RA Duct and Screw Locations
●
3.
Remove the RA duct panel covering the RA
operwg if it has not already been removed by
the installing contractor.
Install the bottom track:
9 Refer to Figure 5 and remove the 8 screws for
15 ton or 11 screws for 20 and 25 ton units
securing the dnp and bottom pans along the
bottom inside of the unit. Save the screws for
installation later.
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Screw ~ I
iUBottomTrack
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BottomPan
‘ DripPan
Figure6: Installing Bottom Track
9
Position the bottom track so that clearance
holes in the bottom track match the unit hole
pattern. Use an awl to al!gn the holes.
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Crank Arms
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Figure 8: Connecting Linkage
Remove the nuts attached to the swivel ball
joints on the linkage arm. Retain for future
use.
Align the two swivel ball joints attached to the
linkage arm with the crank arms attached to
the RA damper blades.
Insert the swivel ball joints into the top holes
of the crank arms and secure with nuts.
Use two 7/16 inch wrenches to tighten and
secure the swwel ball joints.
/
—-
m—
6.
Install the OA damper:
●
Remove the outdoor air damper from the
packing material.
? .— —
-——
—.+—+
—–
Figure 9: Installing Return Air Damper
●
.
With the blue Identification label facing up in
the lower left corner of the damper, position
the lower edge of the damper on the bottom
pan.
Figure 12: InstallingOA Damper
●
Slide the RA damper on the edge of the
bottom pan until the bottom flange of the
damper is past the bottom track.
●
●
●
Lift the RA damper up past the top flange and
pull the RA damper towards you until the
damper is positioned in the bottom track.
TOEIFlar
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Heating
e
F-
Compartment
RADamper
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Slide
I
Figure 10: Positioning Return Air Damper
Slide the RA damper to the left until the seal
contacts the heating compartment wall.
Top LIP ‘
Self-Drilling
TopFlange
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Screws
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Damper>\.
‘“
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.
Figure 11: Securing Damper To Top Flange
●
4
Lift the top of the OA damper up past the top
flange and push the damper towards the RA
damper along the bottom track, and rest it on
the top flange.
Rest the RA damper on the top flange.
{
.
With the blue identification label facing up in
the lower left corner of the damper, set the
bottom of the OA damper into the bottom
track from the filter access area.
Fasten the damper to the top flange using pilot
holes and self drilling screws provided. Refer
to Figure 11. No fastening to the bottom track
is required.
Figure 13: Initial Damper FrameAlignment
●
To aid the installation of the damper assembly,
slide the OA damper to the left until the frame
overlaps the RA damper frame as shown in
Figure 13.
—-
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Frame Overl~
Damper .,~
,
,y
Heating
Compartment
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Center Suport
Notch
i
Verhcal Supporl Bars
4
I I Bracket
Figure 16: PositioningOA Damper
I L(
●
From the OA compartment near the filters, pull
the OA damper towards you ahgrmngthe notch
m the damper flange with the support bar.
I
I
Figure 14: Re-installingCenter Support Bracket
I
Figure 17: Damper Frame Alignment
7.
On 20 and 25 ton units, install the two support
brackets previously removed:
With the supporl bracket at an angle to the
base, Insert the slot between the two bracket
pieces over the lip of the flange
●
A
1
●
At this time, the RA and OA damper frames
will not overlap.
Fasten the OA damper to the top flange using
the self-drilling screws and pilot holes
provided. Use an awl to align the holes.
,J+&%M1-:
CAUTION: Lift the roof when installing the
support brackets to prevent
tearing the roof seal.
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Bladesshown parhally open for clarlty
●
●
8.
Note:
Align the bottom holes, lift the roof and rotate
the bracket to a vertical position.
Use the screws prewously removed from each
bracket to secure,
securing the OA damper:
●
Remove and keep the nut attached to the
swwel ball joint on the linkage arm.
●
Align the swivel ball joint attached to the
actuator linkage arm with the crank arm
attached to the damper blade. This procedure
will open the RA damper blades while the OA
damper blades will remain in the closed
position.
●
Insert the swivel ball joint into the bottom hole
of the crank arms and secure with nut.
Tape
Wrap
Foam Tape Length ~
Damper
Figure 18: Connecting Linkage Rod
>
Figure 15: Foam Tape InstallationLocation
●
Using the 1/8 inch foam tape supplied,
measure and cut a length that will fit the long
edge of the damper frame that will rest against
the access panel.
9
Use two 7/16 inch wrenches to tighten and
secure the swivel ball joint.
5
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Olscharge
Alr Sensor
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support
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Figure21: InstallingDivider
Figure 19: Flange Screws
9.
Use a 5/16 inch driver to remove the 2 screws
located in the floor flange between the return air
and outdoor air compartments and save for future
use.
.
\
o
Apply Foam
\.\Ta~e
To Edge
●
Slide the divider into position against the return
alr damper.
●
Use the 2 screws removed in step 9 to secure
the RWOA divider to the floor flange.
●
Use two self drilhng screws to secure the
OA/RA divider to the support bracket.
●
Use 4 self-drilling screws to secure the RA/OA
divider to the RA damper frame using the pilot
holes provided.
●
Fill the gap at the base of the divider with one
inch foam tape provided.
●
On single enthalpy units, mount the enthalpy
sensor to the metal surface on the RA/OA
divider, On dual enthalpy units, mount the
second enthalpy sensor on the insulation
surface. Use two self-tapping screws to
secure.
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Figure 20: Applying Tape To Divider
10. Install the RA/OA divider:
●
●
6
Remove the return air/outdoor air divider from
its packing material.
Using the 1/8 inch foam tape supplied, apply a
length that will fit on the diagonal edge of the
RAIOA divider.
—
Routed
~ ----Cables
\
. . -Cable
.
Table 1: Sensor ConnectionTable
Hole
T
,
WireConnection
20
25 Ton
SensorType
Ton
II
I
Relays’
‘1
Enthalpy:
O.A. (+)
O.A. (-)
R.A. (+)
R.A. (-)
1
~
,/
Actuator
,
4
—
Figure 22: Installing Cable Assemblies
431 (PR)
432(R)
433 (BL)
434 (o)
2 Leads
●
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s.
+R
SR
2-pinMate-N-
Lock
1
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11. Mounting sensors and wire harness
●
428 (BK)
429(W)
430((R)
431(BL)
T
T1
None
417 (BR)
TR
25 Ton
432 (BL)
TR1
Harness
434(PR)
1
426(R)
3
421(Y)
2
.
Make all wiring connections as shown in
Table 1.
DischargeAir
Temrwaturs
0
Logic
Module
15&
Vertical Support Bracket/
I-ieatmg Compartment Wall
Cut the wire tie securing the cable harness to
the damper.
Insert the 9 pin connector to the unit
economizer plug near the filters.
u
Heating
Compartment
RA Compartment
1
Screw
r1
~
Discharge Alr
~ Sensor
Figure25: InstallingDischargeAir Sensor
Figure23: Routing Cables
●
Uncoil the remaining wiring harness and route
through the round hole in the top f(ange. Allow
the wires to hang in the OA compartment.
●
Locate the discharge air sensor mounting
location on the heating section wall. Mo~nt the
sensor bracket provided using one self-tapping
sheet metal screw.
.
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Tie
Wrap
/ Holes
Cable Routing
J401e
RA Enthalpy
‘ensor
,,
~JA Entalpy
II‘ [
I ‘ensor
\
C>C
? 3 Enthalpy
d J Sensor Mounting
Holes (2 per sensor)
\
— . ----
Figure 24: Component Location on RA/OA Divider
L
●
Route the long wires through the round hole in
the RA/OA divider.
7
Figure 27: Installing Blank-OffSection
12. For 20 and 25 ton units only:
●
Remove the blank-off sechon from the
packaging.
●
Using the 1/8 mch foam tape supplied, apply a
length that will fit on the long edge of the
blank-off section which contacts the access
panel.
9
Insert the blank-off section through the side
access opening of the OA compartment,
●
Use the pilot holes on the top flange for the
self drilhng screws provided to secure the top
of the blank-off section to the top flange.
●
Install one inch foam tape around the cut-out
for the vertical support bracket.
Figure 26: Grommet Installation Locations
●
Insenlthe wire harness into split grommets and
push the grommets through each hole that the
wires pass.
●
Use tle wraps to bundle the wires and secure
to the top flange and RA/OA dlwder as shown
in Figure 23 on page 7.
IMPORTANT:
When securing the wire harness,
insert a loop between the two tie
wraps so that the wire harness
does not rub on the damper
frames during operation.
13. Damper assembly is now complete. Proceed to
the hood assembly instructions.
8
—
I
Economizer Hood Assembly Procedures
-
Note:
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If the dampers were field installed, proceed to
Step 2. If dampers were factory installed, start
with Step 1.
Looking Into Outdoor Air Section
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/’
“ Return Air Compartmnet
,/
Access Door
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p“
‘Tab
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Figure30: InstallingHood Lower Filter Bracket
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Lower Filter Bracket
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‘ Typical Panel Latch ‘
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Outdoor Air Compartment
Access Doors
Figure 28: AccessTo Dampers
5. Remove the lower filter bracket from the packing
material.
6. Angle the lower filter bracket to insert the right tab
into the slot in the right side panel and lower the
hood bottom resting it on the frame of the rooftop
unit.
1. Remove the three access panels (return air
compartment and two outdoor air compartment) by
using a 7/16 inch hex socket to loosen the screws
securing the rotating latches.
\~Rooftop
Cabinet
Figure 31: Left Side Panef Looation
7.
Remove the economizer hood left side panel from
the packing material.
ICenterSuppori Bracket
Figure29: Right Side Panel
2.
Remove the economizer hood box from the unit
and remove the right side panel from the packing
material.
3.
Install the economizer hood right side panel
against the lip of the vertical corner of the rooftop
unit matching the holes in the right side panel with
the holes in the frame.
4.
Insert and fasten six self drilling screws supplied
with the hood kit. Use a 5/16 inch driver to tighten
screws.
●
~:2-
Left Side Panel
D
‘:
Figure32: Aligning Left Side PaneI
8. Tilt the left side panel towards the right as shown
in Fiqure 32 and position the side panel so that the
tab f;om the lower filter bracket can be inserted
into the slot m the side panel.
9
—.
Left Side
Self-Drilllng
Screw
——.
Figure 33: Securing Left Side Panel
Return the left side panel to the vertical posltlon
and ahgn the holes in the left side panel with the
holes In the center support bracket.
9.
10. Insert and fasten six self drilling screws supplled
with the hood kit to secure the side panel to the
center support bracket. Use a 5/16 mch driver to
Push
Hold and
Here ,‘ push Here
,=—
Figure36: Installing Middle To Left Side
13. Push the left side panel to the left and raise the
middle section until the back tab fits Into the slot In
the left side panel,
14. As the left side panel and middle sections are
being guided towards each other, inserf each tab
mto the corresponding slot.
./——
____
P
- ——
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Figure 34: Economizer Hood Middle Section
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11. Remove the economizer hood middle section from
the packing material.
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Tabs and Screws
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Figure37: SecuringTabs
15. Bend the two tabs of the lower filter bracket up and
bend all of the tabs from the middle section down.
Tab
slot
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Lerl Stale
Panel
Right Side
Panel 1
D
Looking Into
Outdoor A!r Section
16 Install and tighten the self dnllmg screws into the
pilot hole of each tab.
17 Remove the economizer hood top from the
packing material.
Figure 35: Installing Middle Section To Right Side
12. insert the tabs of the middle section Into the slots
of the right side panel.
Note:
10
The tabs are bent slightly down from the
factory to facihtate retammg posklon
———.
-————
Note
If the barometric damper is to be installed, do
not install the screws on the left side at this
time.
21. Seal all seams and tab edges with silicone caulk
(not provided).
Figure38: Top Section Location
17. Lift the hood top and lay the edges on the right and
left side panels and push the hood top towards the
rooftop unit frame.
Figure40: Installing Fitters
22. Install the filters inside the top and bottom sections
of the economizer hood assembly.
Figure 39: InstallingTop Section
18. As the top nears the frame, lift the hood top and
continue pushing until the edge of the top clears
the top lip as shown in Figure 39.
19. Lower the hood top making sure that the edge of
the hood top catches the lip of the frame as shown
in Figure 39.
20. Install the self drilling screws along the top first and
then along the hood top to the side panels.
Manually tighten the screws to prevent stripping
the holes in the sheet metal.
A
CAUTION: Care must be taken when using
cordless drivers that the screws
do not strip the metal pieces.
Figure41: Completed Assembly
23. Install and secure the right side OA, filter, and RA
access panels.
11
NOTES
[email protected] to [email protected] IWOC4Primed In U.S A
[email protected] Unitary Prcducts Group 1SS5 All [email protected] rmmmd
Unitmy
Producta
GrouP
Pod Oitlce
Box 1592
York
Pennaylvanla
1740s-1592
SHU
7M
195
66
Codes SBY,F,L
44.320.2
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