INSTALLATION MANUAL FOR 'M' SERIES
Contents
1. A SO 210 4 pro ALON 339 sue HAT 1 mia Le 31509 dWV SL LON LOANNOOSIG A0 c 80c GASNA OL co MEM EMEN ma 31ON 33S nag Hg A g 8 M L amm amm amm d Ede s 9 m 5 1 mim jossa1dwog 1 8 1 4 m O E E EEE me 31939 A u009 w gt O S Nom Ce fo e UI9 s S 02100 d Bod M L LON Ha lt 4D2u 21442242 1VOIdAL Heec cu Mo X spy wa4sks 9500013 40 4524 4240M soy 4545 JI Tp00013 OF E IVISOWHSHL W24MS NVA 4D4soUu42u4 0 4 p2alrj pow 0700013 SRE ESE SNS WOIdAL sua4s s dung 2 4uduablujay Joy Copyright 2010 Unico Inc Wiring Schematic for Cooling Only or Heat Pump without Su2. UPC 01 4860 24 30 619 x 775 Pi Fi 2 2 74 P 4 7 48 6 0 m mun Mc a NCC UPC 01 4860NC 20 30 518 x 775 roof installation requires mounting on blocks with a sheet metal cover or cap to protect the unit from rain and extreme weather conditions zx Be sure to position the return air box and filter near the pL unit allowing at least one 90 bend in the return duct for T proper acoustical performance refer to figure 3 for a y 2 3 typical horizontal attic installation The section on Re Top View 1 1 1 meer Betur Duci turn Air Ducts in the manual provides more details E All modules except the MC4860 cooling module are Z fd C designed to fit through a 14 inch 356 mm opening typical of joist spaced at 16 inch 406 mm center dis Optional Control B f f gy Placement tance MC4860 module requires 18 5 inch 470 opening If no access is provided an opening must be cut It is suggested to use the opening required for the Service clearance 22 4 4 30 762 forMH MC2430 return air box especially in an attic installation The M SN opening for the return air box is listed in Table 1 If the joist
3. CM 6 5 SARA d CER MN 7 un o E 18 6 02100 WM t ILON 39 8 NOIL93S YOOGLNO JeMod TWOIdAL SS jeuondo UOWWOD IVLSOWYSAHL WOIdAL 3505 dWV St H3AO LON 193NNO9SIQ A0 c 80c AGASNA OL Xog WOlYLOATA ACISLNO YO4IMS NY 4D4souJ2u4 044u02 04 PalJIPOW 4Dau jou swaysks dung 40 4 Heat Pump with Supplemental Hot Water Heat second stage Modified to control ventilation speed at thermostat IC hemat iring sc W Figure 25 Copyright 2010 Unico Inc STARTUP IMPORTANT The most important step when installing the Unico System is making sure it has the correct airflow Be sure to record the amperage and voltage of every system in order to verify the airflow through the unit Also measure the airflow at each outlet to verify the airflow in each room Both me thods are described later in this section Sequence of Operation The sequence of operation depends greatly on the op tions installed and type of control thermostat used Most thermostats have a fan AUTO ON switch When the fan switch is set to ON the G circuit 1s closed and the blower relay is energized The indoor blower starts after about a 20 second delay
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5. IVLSOWYSHL WOIldAL YOLIMS 4D4SoUlJ2U4 044U02 O4 palJIpow 4D2u 21419212 5 45 5 dung Heat Pump with Supplemental Electric Duct Heater second stage Modified to control ventilation speed at thermostat IC hemat iring sc W Figure 24 Copyright 2010 Unico Inc Page 20 Bulletin 30 20 1 00073 uMous SD DUIWU24 04 2AOW2Y 40420J U4 4D DUIWU24 4 Of pa422uuoo SI SIU IVNOLLdO SI LVLSVNOV INIT HOS GALVY SLOVLNOO ANY 1109 Ave AV 13H MOHHL 318n0Q 3104d 318n0 LNAIVAINOA HO 101 2228 120ON 114 SI TAGOW Q3GN3WINOO3H OOINN Ad GalIddNS LON SI AV T3H TIOHINOO 1V3H AON39H3IWNH NMOHS SV STVNIINH3 L OL SQV31H2OVv LLV A1314 H 0098709IN ANY H O2v9 OIN H O08 v2OIN S 13GQOW S311nQOW LNVH39IHJ3H HLIM G3SN SI TOHINOO LSOHJ ILNY SSINGOW ASSHL d3sr N3HM NMOHS SV TIVLSNI 01315 HO98YON ANY HZY9EON HOEYZON TIAON AINGOW 9NIIOOO LV3H Q3ddlHS SI AVT3H SSVdA8 LSOHG LINV AYIM 39NVHO JHL NO QVv313H 1 ALVINSNI IVNIINH3 OL 3HN93S ANY QV31 H3INHOJSNVHL GSLOSNNOONN Woud 3dVL SAOWSY 31V ITI SNI ANY TVNINEZL 3HL LV QV3 1 H3 HOJSNVH L 3AOW3H 5531 A802 SI
6. Naa JJ Z m O Z ep O gt LL e A gt 2 b CAPACITOR oo LO o 10 T EAM SEE NOTE 4 C FORMER Lu n gt BLK DO BLK 0 FZ COMMON 208V 230v ANTI FROST 1 T CONTROL E HEAT PUMPS ONLY p aibi das Nes SEE NOTE 3 2 ORG IH E 00 EQUIPT GROUND R WARNING NOTES BE SURE TO INSULATE THE UNUSED TRANS FORMER LEAD TO PREVENT INJURY OR e IS ENERGIZED ON HEATING CONNECT TERMINAL NO 4 DEATH FROM ELECTRICAL SHOCK 2 IF MEASURED SUPPLY VOLTAGE IS 208V OR LESS REMOVE ORANGE TRANSFORMER LEAD AT THE TERMINAL AND INSULATE WITH TAPE REMOVE TAPE FROM RED UNCONNECTED TRANSFORMER LEAD AND SECURE TO TERMINAL INSULATE THE LEAD ON THE ORANGE WIRE 3 ANTI FROST CONTROL BYPASS RELAY IS SHIPPED WITH HEAT PUMP COOLING MOD ULE MODEL MC2436H AND MC4260H FIELD INSTALL RELAY AS SHOWN WHEN USED WIRING LEGEND WITH THESE MODULES FACTORY 4 ANTI FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES _ __ __ __ __ _ MODELS MC2436C H AND MC4260C H FIELD ATTACH LEADS TO TERMINALS AS FIELD NEC CLASS 1 SHOWN FIELD NEC CLASS 2 Figure 21 M Series Electrical Wiring Diagram without Motor Controller installed for A00175 G03 Control Box Copyright 2010 Unico Inc Page 17 Bulletin 30 20 uMous uMous SD 24 Of 422uuo2
7. 20 Heating Module Return Air Adapter MH2430 3660 Heating Module HW2430 3660 Hot Water Coil MB2430 3642 4860 Blower Module 52 UPC 59B 2430 3642 Cooling Module js Return Air Adapter 4 UPC 104 2430 3642 WONDO502 0504 0752 0754 Fits All Sizes 9 WON1002 1004 1502 1504 Fits MB2430 3642 4860 HW2430 3660 WON2002 Hot Water Coil Fits MB4860 Electric Heater MC2430 3642 Cooling Module MR2430 MR3660 Multiple Return Module If using multiple returns replace single return adapter with the correct MRxxxx module where xxxx stands for unit size IL00316b cvx Figure 29 Horizontal Configuration Chart Copyright 2010 Unico Inc Page 27 Bulletin 30 20 O99EMH 10 peddius jeued 55927 098 9 01 4938M JOH O99EMH O PZMH X P 92007 e npo A 1221181 098V CV9 O VCAN ejnpoyy umay 099 MIN O PZMIN EX 5 jeued doy 4 jeued J 14 18918A 5 5 uunja3 ejdniniw 10 4 enpon Buijoo5 098 sou je 4 ejeid dug MOWY 9 npo N 1e eds vy9 9dN v 9 94n e npo N Jemolg 098v CV9 O vcalN einpojA Je2eds Vvr9 Odn Vv9 Odf Ue peddius SI O98POW vp9 Odn ue peddius jou 5 098 PAIN 1 AjeAoedseJ 9 pue eui uiM peddius 9 4
8. The following paragraphs de scribe the sequence of operation when the fan is set to AUTO If the fan switch is set to ON the sequence is the same except the G circuit is always closed and the indoor fan is always operating Cooling Cycle A C or Heat Pump When the thermostat calls for cooling the Y and the circuits are closed and a 24 V signal is sent to the compressor contactor in the outdoor unit and fan relay in the indoor unit After about 20 seconds the indoor blower starts At the same time the compressor and outdoor fan also start Depending on the control circuitry in the outdoor unit there may be a time delay before the outdoor unit starts If the system was just turned off the time delay could be as much as five minutes The cooling system is now op erating For heat pump thermostats setting the switch to cooling immediately closes the O circuit which is used to energize the reversing valve solenoid if required by the heat pump Otherwise the B circuit which closes when switched in heating is used to energize the revers ing valve solenoid Refer to the heat pump manufactur er s instructions to see which mode the solenoid needs to be energized whether in heating or cooling When the thermostat is satisfied the 24 V signals are opened and the outdoor unit stops The indoor blower continues to operate for about 40 seconds then stops The system is now off Heating Cycle H
9. measure the refrigerant liquid line pressure and tempera ture AT THE EVAPORATOR To measure sub cooling use the following procedure 1 Measure and record the liquid line pressure using an accurate refrigerant gauge Record the corresponding saturation temperature for this pressure see Table 8 2 Measure and record the liquid line temperature using an accurate metal or glass thermometer or thermo couple Tape or strap the sensor firmly against the surface of the liquid line and cover with insulation 3 Determine the sub cooling with the following equa tion Saturated Temperature Liquid Line Temperature Subcooling If the sub cooling temperature at the condenser is low the system is undercharged and refrigerant must be add ed CAUTION TO PREVENT DAMAGE TO THE COMPRESSOR DO NOT ADD LIQUID CHARGE INTO SUCTION PORT Copyright 2010 Unico Inc Bulletin 30 20 Page 24 If it is high the system is overcharged and some refrige rant must be removed and collected in an empty refrige rant container DO NOT RELEASE REFRIGERANT INTO THE ATMOSPHERE In some cases such as in a hot attic the liquid line will pick up heat and lose its sub cooling This will be appar ent if the sub cooling at the evaporator is low In these cases the liquid line should be insulated or strapped to the suction line and both insulated The same problem can occur for long refrigerant lines in this case increa
10. 2 to 2 5 ton A00805 A00805 3 to 3 5 ton MC3642C 1012 00805 00805 3 004 014 kW 4 to 5 ton MC4860C 141017 00805 805 4 kW 005 015 Heat Pump Coils 2 to 2 5 ton 00808 00808 2 3 to 3 5 ton MC3642H 10to12 00808 00808 3 004 014 kW 4 to 5 ton MC4860H t4to17 00808 00808 kW 005 015 Copyright 2010 Unico Inc Water Connections If you are installing the hot water coil remove the side coil access panel and cut away the insulation Slide the coil into the cabinet and secure with brackets supplied with the hot water coil Install the access panel after the coil is in place All water connections are 7 8 inch 22mm sweat con nections Sweat the water connections then fill the sys tem Bleed the air from the coil by backing off the screw inside the bleed valve for venting Fig 16 If unit is in an unconditioned space below freezing care must be taken not to freeze the water in the coil The best method 1s to use a glycol water antifreeze solution with a freezing point below the coldest temperature expected After venting the chilled water coil replace the access panel and seal around the connections with the rubber gasket provided Coil Cleaning The coil should be sprayed with liquid detergent or any commercially available evaporator cleaner solution tho roughly and rinsed thoroughly before installation to
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12. and will have some reduction in motor life between the maximum operating temperature and the recommended temperature limit Depending on the ap plication this may or may not be acceptable Recommended Temperature Limit For maximum motor life we recommend that the Unico EC motor be limited to applications with less than 130 F 54 C air temperature Therefore the Unico EC motor can be used with all heat pump and electric heating ap plications without problem It may also be installed with a hot water coil with air temperature leaving the coil less than 130 F 54 C This is generally with water tempera ture less than 135 F 57 C but it depends on the water and air flow Consult the hot water coil specifications to determine air temperatures based on water flow and air flow rate Maximum Operating Temperature Limit The absolute limit for the motor is 158 F 70 C air temperature at which point the motor will automatically begin to slow down The motor may be used in applica tions with air temperature around the motor between 130 to 150 F 54 to 65 C typical for boiler systems with water temperatures between 135 and 160 F 57 to 70 C However expect the life of the motor to be re duced by as much as 50 In most applications with unit operating intermittently the amount of time that the motor operates in heating is very small so the reduction in motor life will not be significant Only in long conti nuous heating app
13. as sure proper drainage of condensate from the coil This will eliminate blowoff and assure maximum coil perfor mance If not sprayed approximately 50 hours of break in time are required to achieve the same results WIRING WARNING Disconnect electrical supply before wiring unit to prevent injury or death from electrical shock All electrical wiring must comply with all local codes and ordinances Blower module controls and compo nents are bonded for grounding to meet safety standards UL Standard 1995 and CAN CSA C22 2 No 236 and are listed by ETL All 50 Hz units are CE marked and conform to the Low Voltage 73 23 EEC and EMC 89 336 EEC Directives Use a separate 1 ph 230 208V 60 50 Hz power supply with a 15 amp breaker and appropriate wire gauge per code Two different control boxes are available one with a variable ventilation speed control one without All stan dard units include a variable speed motor controller to adjust the proper airflow for constant ventilation where required by code or desired by the resident The ventila tion speed is adjustable down to half airflow Control BoxMo Ventilation p Wiring Standard A00175 G03 No ias aei ad Fig 21 Europe Bulletin 30 20 Page 13 The control box includes a 24 volt transformer the ne cessary blower relays and terminal blocks Space is pro vided for a heat pump heating mode bypass relay shipped with heat pump cooling module Space i
14. condensing unit will cycle on the anti frost switch This may reduce the cooling capacity at a time when the cooling load is still fairly high To provide better control and comfort install a low ambient control on the con densing unit Typically a low ambient control is neces sary when operating the unit at outdoor temperatures below 80 F 26 6 C especially for a 5 ton nominal capacity system These controls come in different configurations such as the Hoffman Controls Corp series 500A A head pressure control This control modulates the outdoor fan to main tain a minimum liquid line temperature Other controls may cycle the fan on off In either case check with the condensing unit manufacturer to determine what controls are compatible with the condensing unit R 410A Puron Refrigerant Puron is a registered trade name for refrigerant R 410A by Suva a Dupont Company which is an alternate to refrigerant R 22 In 1987 scientists and government officials met in Mon treal in response to the growing pressure to preserve the earth s ozone layer The outcome of the meeting was the Montreal Protocol an internationally binding action plan to eliminate ozone harming chemicals Chlorofluo rocarbons CFCs such as R 12 were targeted first since they caused the most damage to the environment A cap was placed on the production of CFC s and in 1996 by law all manufacturing was required to cease The Montreal Protocol s next p
15. possible See Bulletin 40 30 Component Duct Layout Design Provide minimum clearance on both sides for servicing the unit as shown in Fig 2 Heating Only Cooling Onl Heating and Coolin Heating and Cooling M4860 Horizontal LE Flow 4 4 Ip 4 Blower Module Vertical P Spacer Module Up Flow Cooling Module Vertical Plenum Vertical Plenum 7 Module without Hot Module with Hot Water Coil Water Coil Heating Module ss with Hot Water Coil Vertical Counter Flow o SNS Normal Air Inlet Outlet lt Optional Air Inlet Spacer Module f IL00010d CVN Figure 1 Basic Module Arrangement refer to detail figures shown on Pages 26 and 27 Copyright 2010 Unico Inc Bulletin 30 20 Page 3 5 127 Minimum for 0 Box Cover Removal Table 1 Retu m Air Box Opening Optiandfcontd B B i T 2 je va is DP E ff if FN y ow ov J g gy f Return Air Box Size of opening A FLA cR P Models mud inches mm 4 x d 1 25 Minimum Fou t 3 1 Air Flow Side View Return Duct 2430 UPC 01 2430 1436 x 25 365 648 1 25 Minimum 143 30 1 365 x 775 Supply Plenum MBxxxxx MCxxxx MHxxxxx u j 3642 UPC 01 3642 x 15 X guru
16. vertical spacer module Horizontal Platform Mounting Mount the unit horizontally when vertical height is li mited such as in an attic or crawl space It is easiest to mount the unit on a platform but care must be taken to assure proper drain line pitch Rafter Joist or Floor Sore ne cu IL00036a CNV 3 Modules 40 1000 40 1000 42 1070 30 760 42 1070 50 1270 See Table 3 Figure 8 Typical Platform Installation The platform height must allow for proper pitch of the condensate drain lines at least 4 inch drop per lineal foot 20 mm per meter The platform can be built from a sheet of 2 inch 13 mm plywood and stud frame Ta ble 3 lists the maximum horizontal drain line run for various framing materials and still provide adequate drainage Table 3 Horizontal Distance of Drain Piping for Different Framing Materials The platform size must allow for the number of modules being used For dimensions for minimum platform size see Fig 8 Place secondary drain pan on platform and unit on top of isolation pads inside of secondary drain pan Be sure that the unit is raised above the height of the drain pan side to allow duct connections Horizontal Suspended Mounting CAUTION Do not hang unit from top of unit cabi net as this could distort unit The modu
17. 206 398 10 32 8 62 4 12 34 8 65 4 a ae 42 229 434 16 38 8 718 711 241 493 18 40 9 751 10 253 uis 20 43 1 78 5 9 266 493 22 45 3 82 1 8 279 513 24 47 6 85 7 F 293 534 26 50 0 89 4 6 306 556 28 52 4 93 2 320 578 30 55 0 97 2 32 57 5 101 ii BEN 1 34 60 2 105 2 ios 36 629 110 2 365 One 38 65 7 114 1 381 673 40 68 6 119 0 397 698 42 71 5 123 1 413 723 44 74 5 128 2 430 750 46 77 6 133 3 447 777 48 80 8 138 4 465 804 50 84 1 143 55 92 6 156 2 60 102 170 iu 7 520 891 8 540 922 90 168 274 9 559 953 95 182 295 10 580 984 100 196 317 12 622 1050 105 eti 341 14 665 1120 110 226 365 115 243 391 120 260 418 30 1090 1780 125 278 A 32 1150 1880 130 297 477 34 1220 1980 36 1290 2090 38 1360 2200 40 1430 2320 42 1510 2440 44 1590 2560 46 1670 2690 48 1750 2820 50 1840 2960 52 1930 3100 54 2030 3250 Copyright 2010 Unico Inc Bulletin 30 20 Page 26 gt UPC 104 2430 3642 4860 Single Return Heating Module System P d Return Air Adapter Configuration ie Ea gina UPC 104 4860 f Heating Module Return Air Adapter MH3660 Heating Module A00557 G01 Spacer Module Cooling Module shipped with MC4860 0 ee jn UPC 59B 4860 T co Cooling Module gin d amp Return Air Adapter tif a A00557 G01 MC4860 na dre Re aly 60 jin UPC 104 2430 3642
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19. 3 8 inch 9 5mm OD and the suction line is 7 8 inch 22mm OD Refer to the condensing unit manufacturer s instruction for proper line sizing infor mation based on distance from condenser Install a liquid line filter drier as close to the coil module as possible to protect the evaporator from foreign object debris For attic installations or when using long line sets an optional moisture indicating sight glass should also be installed between the filter drier and expansion valve near the indoor unit All refrigerant coils require a thermostatic expansion valve The valve is shipped loose and should be attached prior to charging If the system will be using R 410a be sure to use the R 410a valve these can be ordered sepa rately as shown in Table 6 Always use new Teflon seals when replacing the Unico Part No 00809 001 Remove side panels as shown Copyright 2010 Unico Inc Bulletin 30 20 Page 12 m Tighten the pressure tube nut as shown LITE iic o C ope s 4 i 4 1 m AM Y NT a e MT eee 2 Attach and tighten lower connecting nut as shown The thermal measuring bulb is placed as shown It needs to be in contact with copper tube A Secure bulb with cork tape as shown Table 6 Expansion Valve Model numbers Nominal Valve Part Number Nom Condenser Valve Size R 22 R 410a Size Air Conditioning Only
20. 30 20 Page 4 UNIT ASSEMBLY The units may be assembled either horizontally or verti cally Refer to Fig 1 for your particular flow arrange ment Assemble the units two modules at a time If you use a refrigerant coil the anti frost switch wires must be routed to the control box as you connect the modules Anti Frost Switch Wires Remove the coil access panel and unravel the anti frost switch wires If you use a heating module feed the wires under the hot water coil support channel Then feed the wires through the bushing in the motor partition panel After routing the wires through each module connect the modules together Fastening Modules Together To fasten the modules together tilt the units to insert the connection flange over the mating flange as shown in Fig 4 It may be necessary to squeeze the units together as you are inserting the flange to compress the rubber gaskets If the hook flange has a small gap use a large flat bladed screwdriver to pry the gap apart Secure the modules together with the latches compressing the gasket further A N 2 N N T P ZF j G IL00009 CVS Figure 4 Module Flange Connection EC Motor Temperature Limits The Unico EC motor includes an electronic circuit board that is sensitive to overheating 1f the air temperatures surrounding the motor are above a certain value The motor will not function above its maximum operating temperature
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22. Bulletin 30 20 Dec 2010 The Unico Systenr IL00004a CVN GENERAL The information on the following pages is to help the installer save time provide the best possible installation and ensure continuous trouble free operation SCOPE These instructions apply to the Unico Series mod ular air handler units For heat pumps refer to Bulletin 30 24 for additional instructions Installation instructions for the air distribution system are covered in Bulletin 30 05 Before beginning any installation a detailed system layout must be done in accordance with the System Siz ing and Layout Procedure Bulletin 40 40 and the Com ponent Layout Instructions Bulletin 40 30 NOTICE TO INSTALLER AND EQUIPMENT OWNER RETAIN THIS MANUAL AT THE JOB FULL BUILDING INSULATION IS ESSENTIAL FOR THE MOST ECONOMICAL OPERATION GENERAL PRECAUTIONS AND SAFETY TIPS Do not attempt to install or startup unit without first reading and understanding the appropriate sections in this manual Before operating be sure the unit is properly grounded Installation should be in accordance with all local codes and regulations and with the National Board of Fire Un derwriters regulations In case of conflict local codes take precedence All electrical wiring should be in accordance with the latest edition of the National Electrical Code and all lo cal codes and regulations The unit is safety certified to UL 1995 and lis
23. Figure 6 Hook flange location Vertical Installations As shown in figure 1 the modular system can also be configured for vertical up flow or down flow The ar rangement of modules is different so be sure to follow these instructions In most cases connecting the modules is straight forward just use the arrangement shown in figure 1 However if you are using a 2430 or 3642 cooling module the top and bottom access panels of the cooling module will need to be repositioned When repositioning the bottom panel it will be necessary to add an insulation piece and remove a portion of the existing insulation to fit properly over the default side return For vertical up flow installations we recommend using the Vertical Return Plenum Module MV module The spacer shown in figure 1s included with the MV mod ule except for the 4860 unit where it is included with the cooling module If you are not using the MV mod ule for the 2430 or 3642 you will need to use the Vertic al Conversion Kit UPC 63A or UPC 64A and provide a field fabricated mount for the unit CAUTION To allow proper condensate drainage do not turn or rotate the 2430 or 3642 cooling module For vertical up flow the return air may enter through the bottom or side return opening of the 2430 or 3642 cool ing module although the bottom is opening is preferred The 4860 cooling only has one return opening for either horizontal or vertical applications The 4860
24. H c 8 m lt E mE m nig C ow ou C C iw O C NE TERES 52 Wave EL Fu lt lt 88 SVHHOLON og 1 30 D 13A 5 28 i TEI ma JJA yg C ce D 2 2 13A m 24 dH i Lo AM A es pi i mM nee Josse1du09 gt 18 TIPMod Eve Ens ed OA EA 9NIHOLV INO neu D c 1 Ge IN S3IH3S Zu EMEN EET 9H SOJJI9 T j dIMYYN SWALI LINO WALSAS OOINf eod SNOLLVTIVLSNI HOS NOLLO3S 3 WOIdAL _ IVISOINH3HL WOIdAL ANO 91800V Figure 20 M Series Electrical Wiring Diagram with Motor Controller installed for A00175 G02 Control Box Copyright 2010 Unico Inc Bulletin 30 20 Page 16 TYPICAL FOR COOLING ONLY INSTALLATIONS Unico SYSTEM M SERIES M naa TYPICAL POWER EP REV VALVE B SEE NOTE 1 HEATING o 0d o HEAT REV VALVE L d 0 T COOLING MEN REV VALVE 20227 COMPRESSOR D L7 ee 9 x LIL HEATING COMPRESSOR TRI lili jj add Ndg
25. HLNOO ONIHOLVINN AV I3H Q33d e SSV19 O3N L 55 12 O3N 91315 ADVLIOA AHOLOVJ 3NI1AHOLOVH AW14 10H1NOO Q334S HOIH 10H1NOO 1V3H AON3OH3IW3 QIN3931 HOLIMS TOHINOD ISONA UNY 2009 LN3NOdWOO GNNOYS LNAWdINOA OjOjJ durs 3LON 33S NOILOAS doodaino M 2 2 A WOIdAL TEM amog IvO0013 ee X uouuop IVLSOWYSAHL WOIdAL Bae ps ae oe De 1 ma 4snad X SL H3AO LON LOANNOOSIC A0 c 80c GASNA OL O OH Q ug Hg ng yg aue 96 ma yg yg H m O m m m m 25 31935 212 916 9 02100 TE YO4IMS NYJ 101SOWU2U4 o44u02 04 PalJIPOW 4D2u J240M oy SW24S S 40 4 th Hot Water Heat ing wi Refrigerant Cooli IC hemat iring sc W Figure 23 Modified to control ventilation speed at thermostat Copyright 2010 Unico Inc Page 19 Bulletin 30 20 uMous SD DUIWU24 Of 12
26. I 1 OL Qv3l YAWHOS SNVH L GASNNN AHL ALVINSNI OL ENS 38 Sv STIVNIWH3 L OL SQV31HOV LLV 01315 H 909879IN ANY H OcP9EOIW H O0EYZON LOANNOOSIG A0Ee 9504 OL S13GON SAINGOW 1 HLIM AINO AASN SI TOHLNOO LSOHJ3HLINV i Sq3 1ndOW 3S3H L Q3Sf ONIN VM QN3931 N3HM NMOHS SV TIVLSNI 07315 HO98YOIN ANY HOETZON TICON AFINGOW dWfd LV3H Q3ddlHS SI AVI3H 55 4 15 76 39NVHO JHL NO SHL ALVINSNI TVNIINH3 L OL 3H093S ANY HAWHOASNYHL Q3 D3NNOOND WOuSs 3dVL 3AONW3H 3dV L HLIM ALVINSNI IVNIINH3I LV QV31 H3l NHOJSNVH L 3AONW3H SS31 HO A802 SI JDVLIOA AlddNS GAYNSVAW Al 76 JO GVALSNI 4 OL v ON IWNINYSL LO3NNOO ONILV3H NO Q3ZIDH3N3 SI SATIVA SNISH3A3H Hl 1 SALON aNnou9 ILON 336 AINO LV3H HET 210 AV 13H SSYdAg 0 6 c one l H3INHOJSNVH L icd ms 3 TBA 9 O lt m 20 C zs 2 m C C 19 1 ILON 339 gt 55 U mNiE i gt T 1SOHJHINV ng 2 p I
27. TO THE WHEEL BALANCE DO NOT GRAB THE ASSEMBLY BY THE WHEEL OR SET THE ASSEMBLY DOWN SUCH THAT THE WHEEL IS SUPPORTING THE ASSEMBLY ALWAYS SET THE ASSEMBLY DOWN WITH THE WHEEL ON TOP Once the assembly is removed the proper service may be preformed If the wheel is to be changed it may simp ly be removed from the motor shaft by loosening the motor set screw and pulling the blower wheel off the motor shaft If the motor is to be changed first the blow er wheel must be removed as mentioned above and then the screws fastening the motor to the inlet ring must be removed To re install the motorized blower assembly back into the blower housing follow the steps mentioned above in reverse order 4 9 x t N Figure 28 Removal of the Motorized Blower Assembly Table 8a R 22 410A Satura tion Pressure Temperature English units Bulletin 30 20 Page 25 Table 8b R 22 410A Satu ration Pressure Tempera ture SI units psig kPa gauge oF R 22 R 410A R 22 R 410A 0 24 0 48 4 18 163 330 2 25 7 51 1 17 174 347 4 27 4 53 8 16 184 363 6 29 2 56 6 15 195 380 8 31 0 59 4 14
28. cles on the electric heating elements The G circuit completes the 24V signal to the fan relay in the indoor unit which starts the indoor blower after a time delay of about 20 seconds The heating system is now operating When the thermostat is satisfied the 24 V signals are opened and the indoor blower stops after about 40 seconds At the same time the sequencer cuts the power to the electric elements The system is now off Note Use a thermostat designed for electric heat A normal heating cooling thermostat will not close the circuit on heating Ventilation Cycle When the thermostat is satisfied and the fan switch is set to AUTO the circuit is open so that power to the motor goes through the varia ble speed controller and the motor runs at reduced speed The speed controller is set by the installer to a specific speed The factory default setting for the speed control is OFF Using the typical wiring schematic the fan will operate continuously if the variable speed control is switched on It will either operate at normal speed full speed or at a reduced speed Use the alternate wiring diagram to allow the user to turn the ventilation mode off at the thermos tat To turn it off simply move the fan switch to the AUTO position Checking Air Flow CAUTION Do not operate blower with free dis charge or low static pressures below 1 inch w c 250 Pa to prevent motor from overloading After
29. condensing unit The system is now ready for refrigerant charge adjustment If the coil is equipped with a threaded TXV always verify that the threads are tight and do not leak Start up the system and check line voltage to assure it is within acceptable limits for the system as dictated by the condensing unit manufacturer Run the system for 20 to 30 minutes to get reasonably stabilized conditions Do not attempt to adjust charge with outdoor temperature below 75 F 24 C An outdoor temperature of 75 to 85 F 24 to 29 C is preferred If the system charge must be checked when the outdoor temperature is below 80 F 26 7 C block the condenser coil until the head pressure is approximately equal to what its charging chart specifies for an 85 F 29 C day For heat pumps always check the charge in cooling mode If this is not possible because of low outdoor tem peratures charge the system in the heating mode but return later when the weather is warmer before the sys tem is switched to cooling Sub cooling Method Many condensing unit manufac turers publish the amount of sub cooling that the con denser will produce Follow their instructions to charge the unit Typical sub cooling values will be between 3 an 8 F 2 to 5 C The unit should ALWAYS have some amount of sub cooling To be sure there is enough sub cooling especially if the unit is in a hot attic check the liquid line sight glass near the evaporator for bubbles or
30. drain pan is L shaped and will work properly when the module is turned 90 degrees Follow the following steps for vertical installations of cooling only or heating and cooling systems Remove Latches Move Bottom panel Add insulation Filler Panel piece Item A e Install first Trim to fit approx 1 5 inches 38 mm IL00301b CNV STEP 1 2430 and 3642 only Remove top and bottom pa nels and install as shown Install filler panel Item A first then the side panel 1 as shown Remove panel from bottom of the coil bottom of the coil shown Copyright 2010 Unico Inc Bulletin 30 20 Page 6 Add insulation piece centered on the panel This is provided with the MV2430 MV3642 modules or UPC 63A UPC 64A conversion kits Trim insulation as shown Final panel assembly shown UPC 104 xxxx Return Air Adapter Reposition Latches to sides of Module Airflow LS ILO0302 CNV Gasket Tape Module Return Air Adapter AIRFLOW Typical Vertical System Layout IL00303 CNV STEP 2 If using the UPC 104 Adapter reposition the latches to connect to the MV module Cooling Module Latch Keeper shipped loose Gasket Tape Vertical applied to top Heating of MV module Module IL00304a cvx Latches shipped loose Airflow Adapter Note Attach Latches and Latch keepers to appropriate m
31. e reading will be in error You will get a higher reading if the tube is angled toward the air stream Low Static Low Ampe Restrictor set too low rage Low Voltage Blower Wheel not aligned properly Dirty blower wheel Low static high ampe Large number of outlets rage Restrictor setting to high High Static Restrictive duct system Low Amperage Blocked filters restriction in return duct Open restrictor to table 4 setting Clear restriction Check with local utility Center wheel inside of inlet ring Position on shaft for 1 inch 3 mm clearance from inlet ring Clean wheel Close restrictor to proper amperage or Add balancing orifices to outlets Close restrictor to obtain proper amperage Add outlets add splitter vane in tee reduce the num ber of tees and elbows in plenum increase plenum size to 9 equivalent or Open restrictor to proper amperage Copyright 2010 Unico Inc Bulletin 30 20 Page 23 _ To Manometer Tube 2 Plenu m Inside of i Plenum End must be flush AlRFLOow 67 Figure 26 Measuring Plenum Static Pressure In the absence of a manometer you can build a simple but less accurate manometer in one of two ways One way is to use a short piece of ruler or yardstick and clear plastic tubing as shown in Fig 27 To Ruler 2 Plenum about 6 long N Clear Plastic Tubing Static Pressure Reading F
32. eat Pump Setting the thermostat to HEATING will automatically switch the reversing valve solenoid This setting closes the B circuit which sends a 24V signal to energize the solenoid if required by the heat pump Otherwise the B circuit is not used and the solenoid is not energized during heating When the thermostat calls for heating the Y and circuits are closed sending a 24 V signal to the compres sor contactor in the outdoor unit and the fan relay in the indoor unit This starts the indoor blower and the out door compressor There is a time delay of about 20 Bulletin 30 20 Page 21 seconds for the indoor unit The heating system is now operating in stage one If the first stage does not satisfy the thermostat the second stage thermostat calls for more heat This closes the W2 contacts and energizes the sequencer for elec tric heat if installed When the second stage thermostat is satisfied the W2 circuit is broken and the sequencer is de energized The electric heating system is now off When the first stage thermostat is satisfied the 24 V signals are opened and the outdoor unit stops The in door blower continues to operate for about 40 seconds then stops The system is now off Heating Cycle Electric Heat Only When the thermostat calls for heating the W and G circuits are closed The W circuit completes the 24V signal to the sequencer in the electric duct heater which cy
33. ed trans former lead to prevent injury or death from electrical shock The low voltage transformer is factory set for a pri mary voltage of 230V If power supply is 208V re move ORANGE lead from L2 terminal and connect RED lead to L2 Insulate the connector on the un used wire lead TYPICAL UNICO SYSTEM THERMOSTAT AIR HANDLER OUTDOOR CONDENSING 1L00255 CNV TYPICAL HEAT PUMP THERMOSTAT UNICO SYSTEM OUTDOOR AIR HANDLER CONDENSING UNIT W DEFROST HEAT COMPRESSOR REV VALVE COOLING REV VALVE POWER POWER COMPRESSOR REV VALVE HEATING COMMON COMMON EMER HEAT WIRING DIAGRAM AS SHOWN IS FOR A REVERSING VALVE THAT IS ENERGIZED IN COOLING MODE WHEN VALVE IS ENERGIZED IN HEATING MODE USE THE B TERMINAL ON THE THERMOSTAT INSTEAD OF THE O TERMINAL AUX HEAT amp 00000020199 1100062a CVN AUX HEAT Figure 18 Heat pump control wiring without electric heat THERMOSTAT Honeywell T87F Thermostat with Q539A subbase or equal r FAN DPDT RELAY Honeywell R8222D1014 or Steveco 90 340 Relay plus Enclosure or equal HEAT UNICO SYSTEM AIR HANDLER COMPRESSOR BOILER OR PUMP POWER pese COMMON OUTDOOR CONDENSING UNIT POWER COMMON 1L00130c CVN AQUASTAT Figure 19 Cooling with Typical Hot Water Heating control wiring with optional aquastat The controller is set at the factory to provide constant ventila
34. ertical down flow counter flow arrangements it is difficult to provide a secondary drain pan because of the blower discharge at the bottom The secondary drain pan must be fabricated with an opening for the blower dis charge and plenum adapter and still provide a sealed drain pan Table 2 Secondary Drain Pan Dimensions inches mm 2 Modules 3 Modules Unit Gize Part No Dimensions Part No Dimensions EN mm inches mm uPC 94 94 40x22 1016 x 559 i x 29 i 41 40 x 41 751 1016 x 1060 3642 40 x 29 5 40 x 41 751 40 x 541 4860 UPC 24C 1916 x 1060 UPC 24D 1016 x 1372 T NOTE The drain fitting extends 7 8 inch 22 mm beyond this dimension Copyright 2010 Unico Inc Bulletin 30 20 Page 8 Like the modules all the secondary drain pans except UPC 24C D will fit through the return air opening For these drain pans it will be necessary to fold the pans in order to pass through the return opening If you are una ble to use the UPC 24D because of space limitations use the UPC 24B under the cooling and heating mod ules In this case the blower module will extend beyond the secondary drain pan and should be supported with blocks or an angle iron frame MOUNTING The modules come factory ready for horizontal airflow applications and may be modified for vertical airflow arrangements see Fig 1 with the addition of the vertic al heat module with or without the heating coil and the
35. ess of aspiration produces a more even temperature distribution in the room The Unico M Modular Series air handling units consist of various modules that are easily latched together The modules can be arranged in a vertical up flow vertical counter flow and horizontal flow configuration They can be combined as a heating only cooling only or heating and cooling air handler unit See Fig 1 All insulated Unico System modules feature closed cell insulation for improved sound attenuation There is no exposed fiberglass insulation Copyright 2010 Unico Inc Bulletin 30 20 Page 2 Each module is available in three sizes 2430 3642 and 4860 Models with a 3660 model number denote that the particular unit piece may be used with the 3642 or 4860 model There are three basic modules a blower module a cool ing module and a heating module The blower module includes the blower wheel blower housing motor and electrical control box The cooling module includes a cooling only refrigerant coil a heat pump coil or a chilled water coil The heating module is supplied as an empty cabinet with room for a slide in hot water coil The modules can be arranged to provide only the options needed as shown in Figure 1 with details on pages 26 and 27 Heating only systems require the blower module the heating module and a hot water coil Cool ing only systems include the blower module and a cool ing module For heating and c
36. g unit and add the estimated pressure loss in the suction line between the condensing unit and evapo rator Record the corresponding saturation tempera ture for this pressure see Table 8 2 Measure the suction line temperature at the evapora tor outlet using an accurate metal or glass thermome ter or thermocouple Insert the thermometer under the insulation on the suction line and tape firmly against the surface of the suction tube 3 Determine the superheat with the following equation Suction Line Temperature Saturated Temperature Superheat Charging by Gauge Pressures It is not possible to charge the system by gauge pressures Gauge pressure should only be used to verify the system is working properly The Unico System will show a lower suction pressure during the cooling mode than a conventional system Generally it will be 10 to 15 psi 70 to 100 kPa less For example a normal suction pressure for the Unico System will be about 65 psig 450 kPa with an 85 to 95 F 29 to 35 C outdoor temperature Expect lower pressures when the outdoor temperatures are lower The head pressures should be similar to a conventional system when in the cooling mode Using a Low Ambient Control Kit Since the Unico System operates at colder coil tempera tures in cooling mode an anti frost switch is installed on the coil to prevent coil freeze up In certain instances such as when the outdoor ambient temperature is low the
37. hase out targets are hydro chlorofluorocarbons HCFCs including R 22 the pri mary refrigerant in residential heating amp air conditioning products The 1990 Clean Air Act in conjunction with the Mon treal Protocol established January 1 2010 as the date when the U S will ban the manufacturing of products using HCFCs The same document bans the manufacture of R 22 in 2020 Thereafter only recycled R 22 can be Copyright 2010 Unico Inc used The phase out schedule is timed so that R 22 is available for expected lifespan of the R 22 equipment The Unico System is completely compatible with R 410A Using R 410A with the Unico System is a simple matter of changing the expansion valve The refrigerant coil is shipped with an R 22 expansion valve that must be changed to an R 410A expansion valve for the correct tonnage needed Maintenance When service 1s required to the motor or the wheel the entire assembly may be removed as a unit see figure 28 The blower assembly unit is accessible from the piping connection side of the unit It is not necessary to access both sides of the unit Nor is it necessary to dis connect any module or ducting To remove the motor and blower wheel assembly loosen the six 6 screws fastening the motorized blower as sembly to the blower housing Twist the motorized blower assembly counter clockwise CCW and pull the assembly away from the blower housing CAUTION TO PREVENT DAMAGE
38. hat it is within the allowable range With the restrictor plate positioned according to table 4 the plenum static pressure should be 1 4 to 1 6 inches of water column 350 to 400 Pa If the plenum size is 9 inch 229mm diameter the plenum static pressure will be a little greater about 1 8 inches of water column 450 Pa It is not necessary to measure the return duct static pres sure unless it was field fabricated The maximum return static pressure including filters should be 0 15 inches of water 37 Pa If it is greater than 0 15 inches of water column add the return system pressure drop to the supply plenum static pressure to get the total static pres sure drop For example If the supply static pressure is measured to be 1 6 inches w c and the return system pressure drop is 0 25 inches w c the total static pressure drop is 1 6 0 25 1 85 In this case the static pressure is too high Table 7 Airflow Troubleshooting Chart If the restrictor plate is not positioned according to Table 4 the static pressure reading is not an effective indicator of airflow although it should still be recorded In this case measuring motor amperage is the only reliable in dicator Check Motor Amperage Remove the control box cover and measure the current with an amp meter and compare to the Motor Amperage Airflow table enclosed as a separate sheet in the Blower Module carton Check Outlet Airflow Measure and record the air flow f
39. igure 27 U Tube Manometer Setting the Ventilation Speed Constant ventilation is optional To enable constant ventilation simply turn the variable speed control knob clockwise The lowest speed that produces some amount of air circulation is best This is usually the lowest speed position as far clockwise as possible The controller may also be set at any other speed but it is not necessary for ventilation Charging the System DO NOT VENT REFRIGERANT TO THE ATMOSPHERE It is a violation of federal law and in some cases local ordinances also Always use a refrige rant recovery or recycling device If charging a heat pump refer to Bulletin 30 24 Instruc tions for M Series Modular Heat Pump Systems The following procedure is only valid for charging the sys tem during the cooling mode To check for proper charge record the refrigerant pres sures and temperatures Check the refrigerant charge by measuring the amount of sub cooling or approach temperature for some condensing units If the outdoor manufacturer does not have sub cooling or approach temperature charts then be sure that the sub cooling 1s between 3 and 8 F 2 to 5 C For long refrigerant lines or when the evaporator is above the condenser the sub cooling should be close to 8 F otherwise aim for the low end of the range After the refrigerant lines and evaporator have been carefully leak tested and evacuated release the R22 op erating charge in the
40. in 30 20 Page 11 minate the secondary drain line above a windowsill so that the drainage splashes on the window This will serve as an indicator that there is a problem with the primary drain In cases where a secondary drain line cannot be run add a float switch or a micro switch with a paper fuse Refrigerant Coil Connections Note All refrigerant coils are shipped from our factory pressurized with nitrogen They do not contain any refrigerant WARNING To prevent injury to eyes face away from the Schrader valve when releasing nitrogen gas The refrigerant coils are equipped with a Schrader valve port to relieve the pressure and for factory testing pur poses It can also be used to check for leaks prior to in stallation Unscrew the Schrader cap and press the de pressor If there is no nitrogen pressure present the coil may have developed a leak during shipment and should be returned to the point of purchase for ex change If pressure is present then go ahead and relieve the pressure in the coil be continuing to press on the de pressor When all the pressure is removed cut the ends of the connections off Connection after the end has been cut off WARNING To prevent injury remove all pressure from coil before removing connection end caps CAUTION When brazing purge with nitrogen gas to prevent the formation of oxides The refrigerant lines are copper sweat connections The liquid line is
41. ion Copyright 2010 Unico Inc DUCT CONNECTIONS Supply Plenum Unico has a complete line of round and square plenum adapters available as shown in figures 10 and 11 In addition all blowers include a restrictor plate to be in stalled between the supply adapter and the unit The purpose of the restrictor plate is to eliminate objectiona ble outlet noise because the blower is delivering more air than required In most cases where the maximum airflow is required the restrictor may be omitted To attach the plenum adapter first install the restrictor plate Then install the adapter with eight 8 sheet metal screws as shown in Fig 12 Sheet metal screws for in stalling both are provided with the blower The restrictor plate is used to set the system airflow see Fig 13 The full open position corresponds to the high est airflow the installed duct system will allow Set the restrictor plate to the full open position and measure the system airflow The required system airflow is 200 250 CFM per nominal ton 27 34 L s per nominal kW Measure the motor amperage and use this to ensure the 200 250 CFM per nominal ton 27 34 L s per nominal kW has been achieved If elevated sound levels are no ticed at the outlets and there is more that 250 per nominal ton 34 L s per nominal kW the airflow may be reduced with the restrictor plate Always measure the system airflow by the motor amperage see Table 4 Refer to the ai
42. les can also be suspended from the ceiling or rafters A typical suspension method is shown in Fig 9 Screw four 4 J hooks into rafters Suspend four 4 chains from J hooks and attach eyebolts to chains Secure angle iron to eyebolts and place secondary drain pan on top Put isolation pads in drain pan making sure unit sits above sides of drain pan As an alternative rest the unit on the angle iron supports and hang the secondary drain pan from the same sup ports As above install J hooks chains and angle iron Secure angle iron to eyebolts and put isolation padding on angle iron Adjust the length of the eyebolts and chains so there is slight pitch towards the drain end SECONDARY gt gt DRAIN PAN LIT gt IL00038b CVN ANGLE IRON Figure 9 Typical Suspended Mounting Vertical Airflow Installation Because the units are top heavy it is not recommended to suspend a vertical unit It should be mounted on either a platform or a floor Unico makes a module specifically for vertical installations refer to previous section If only a blower and heating module are being installed fabricate a return plenum for the unit to sit upon Although the 2430 and 3642 modules may be assembled without a spacer module this can severely restrict the airflow especially if the blower needs to achieve its maximum airflow Therefore always use the spacer module for any vertical configurat
43. lications will the reduction be notice able The reduction in motor life can be further mini mized by using setback boiler temperatures while operat ing with maximum airflow at the highest water tempera tures Horizontal Installations Most systems are installed in the horizontal configura tion with the air going from right to left when looking at the connections as shown in figure 1 All the modules are factory set for horizontal airflow It is not recom mended to flip the cooling module to reverse the flow direction of the air When connecting the modules be sure to arrange the heating module on the inlet return side of the cooling module The 4860 cooling module also includes a spacer module which has a small drip shelf shipped loose that must be installed on the air exit side of the drain pan shown in figure 5 When installing the heat module or return air plenum module upstream of the cooling module it is necessary to first install a hook flange to the bottom of the cooling coil Figure 6 Spacer Coil Module lt AIR FLOW Plate ILOQ3298 cvx Drain Pan Figure 5 4860 Drip plate installation horizontal applica tions only Copyright 2010 Unico Inc Bulletin 30 20 Page 5 Latch Hook shipped loose with MR module Cooling Module ce Heturn Air Plenum or Heating Module Hook Flange shipped loose with MR or MH unit IL00220a CNV
44. m MR module The MR module is availa ble in two sizes 2430 and 3660 and it includes a central filter The MR module 15 easily fitted to the air handling unit and multiple return openings may be cut in the top back or sides of the box Refer to Bulletin 20 20 6 Re turn Plenum Module for additional information PIPING All piping must be in accordance with all local codes and ordinances Condensate Lines The primary drain pan condensate connection is a 4 inch 19mm female pipe thread fitting and the second ary drain pan connection is 34 inch 19mm PVC sock et fiting Elevate the unit so the condensate lines are pitched at least 4 inch per lineal foot 20 mm per me ter Trap the condensate line near the unit using U trap A00924 G03 as shown in Figure 15 In some cases it may be necessary to wrap the condensate line near the unit with insulation to prevent water condensation on the outside of the pipe In some climates or locations it may be necessary to protect trap from freezing in the winter Pitch 4 inch per foot 2 cm per m 2 1 4 ILOO046a cvx 57 mm U TRAP A00924 G03 shipped with MC modules Figure 15 Typical Condensate Trap Do not trap the secondary drain line and do not terminate line into the primary drain line Run secondary drain line so that any drainage will be immediately known without causing damage to property A typical location is to ter Copyright 2010 Unico Inc Bullet
45. ncluded with the blower Copyright 2010 Unico Inc Bulletin 30 20 Page 10 Return Duct Unico supplies a return duct system but any return duct system is acceptable provided the pressure loss does not exceed 0 15 inches of water 37 Pa including filters The return duct should have at least one 90 bend be tween the unit and filter box to reduce sound transmis sion directly from the unit The Unico Return Duct system has a single return that includes the return air box with filter the return duct and the return air adapter refer to Fig 3 Multiple re turns or extra long returns are possible so long as the maximum pressure loss is not exceeded For vertical installations or tight spaces it may be necessary to fabri cate a return duct system from duct board or lined metal The typical return duct is 10 foot 3 m in length so it may have to be cut to avoid bunching if the distance to the unit 15 significantly less than 100 inches The mini mum length should be 7 feet 2 m When given a choice the shorter distances should be avoided as this may increase sound transmission from the unit Cut an opening for the return box as specified in Table 1 For the 2430 and 3642 if the joists or studs are on 16 inch 410mm centers there is no need to build a frame to hold the return air box Otherwise it will be necessary to construct a frame around the opening For the 4860 return it will almost always be necessary to cu
46. odules on opposite side not shown STEP 3 Place cooling module on top of vertical module Install latches and keepers as shown to secure the cooling module NOTE Attach insulation gasket tape along the top opening of Cooling Module to en sure air tight fit Copyright 2010 Unico Inc Bulletin 30 20 Page 7 Blower Attach both corner brackets not used on 4860 9 Corner Bracket 2 plcs ILO0307a cvx Airflow Return Air Adapter STEP 5 Place the Spacer Module on top of the cooling coil Then place the Blower Module on top of it Secure both modules with latches Heating Only Systems For heating only systems the installation is similar to the cooling only or heating and cooling system except that the cooling module is re moved from the system For the 2430 and 3642 systems with the MV unit use a vertical spacer kit such that the spacer overhangs the back of the vertical plenum and the filter access 1s not covered over Insulation gasket tape which is shipped with the spacer module is installed on the opening of the spacer module Control Box The control box is shipped with the blower module It can be installed on either the discharge side of the blow er cabinet or on top of the blower cabinet depending on what is most convenient To install first remove the two knockouts on the side or top of the cabinet where it will be in
47. ooling all the modules are combined with coils The system may even be used for ventilation only using just the blower module Unico designed and built blowers feature direct drive motors or EC motors and are located in the air stream Each blower wheel is balanced to Unico specifications The blowers feature a quick twist and lock motor mount for easy maintenance see page 16 The motorized blower assembly consists of the motor which is mounted to the inlet ring and the wheel which is mounted to the motor shaft OPTIONS Other options and modules are also available to add ad ditional features or to simplify installation These in clude an electric duct heater multiple return plenum and a vertical plenum stand Please refer to the latest Unico Catalog for information on these and other options UNPACKING All modules are inspected prior to shipping and are care fully packaged in individual cartons Inspect all cartons prior to unpacking Notify carrier of any damage Open each carton to remove the modules Inspect unit for visible signs of concealed damage and notify carrier of any such damage All materials are sold FOB Factory and it is the respon sibility of the consignee to file any claims with the deli vering carrier for materials received in damaged condi tion LOCATION Locate the air handler to minimize the number of plenum elbows and fittings while keeping the supply duct runs as short as
48. pplemental Heat Modified to control ventilation speed mode at thermostat Figure 22 Page 18 Bulletin 30 20 SD DUIWUa4 04 429uuo2 2AOW2Y 40420J 4D DUIWU24 4 pa422uuoo SI 51 1 IVNOI LdO SI LVLSVNOV Q3 1VH SLOVLNOO ANY 1109 Ave HLIM MOUHL 3 18000 310d 318n00 LN31VAInO3 HO 0102228 TAGOW TI3MA3NOH SI TACOW Q3GQN3WIAOO3H OOIN GAlIddNS LON SI AV TH3H TOHLNOO 1V3H AON39H3IN3 NMOHS SV SIVNINHAL OL SQv31HOVvLLV 01315 H 009879IN ANY H Oev96OW H 20 vcOIN S 13GQOW SINON LNVH39IHJ3H HLIM G3SN SI TOHINOO LSOH4 ILNY AYIM 39NVHO JHL NO QV313H1 ALVINSNI TWNIWYSL OL 3HN93S ANY QV31 H3 HOJSNVHL Q31153NNOON qaad 3dv L SAOWSY 3dV L 31V I SNI ANY TVNIAH3 L JHL LV QV31 H3 NHOJSNVH L 39NVHO SAOWSY SS31HO A802 SI AlddNS GSYNSVAW al E SALON 13103 335 420HS 1VOIHLIO3 13 H1V3G HO LN3AdHd OL QV31 YAWYOS SNVuL GASNNN AHL ALVINSNI OL 3HNS 38 iSNINHVM 421108 OL ie vy 3LON 33S umMoys uMous 50 Avjay Aou2bu2W3 04 412euuoo 240124 244 10 purua 4 Of pa422uuoo S SIUL H3I NHOJSNVH L Q33dS HO LIOVdVO NNY YOLOW AV I3H IO
49. pue ve9 odn ve 9 odn 29115 1891481 s jeued 1 eynsu3 syuf 2 9 pue 104 uonej ejsu 89H11 WALSAS O9INN Figure 30 Vertical Configuration Chart Copyright 2010 Unico Inc Bulletin 30 20 Page 28 PAGE INTENTIONALLY LEFT BLANK Copyright 2010 Unico Inc
50. rflow amperage charts provided with the blower Note Do not use restrictor plate to adjust plenum static pressure Adjust the restrictor to the proper amperage This will assure proper airflow Attach the plenum to the adapter by inserting it over the supply adapter If using sheet metal duct use three 3 or mne 2 550165 6053 716 182 10 18 257 Dimension B 325 83 838062 inch mm D 7078 9629 10054 L gt AIRFLOW B E ai Figure 10 Round Supply Plenum Adapter Dimensions a A 4 20151 6 9 5 8 50 216 Mer 3642 10 50 267 UPC 62 4860 11 50 292 iLO23314 CHY yke Figure 11 Square Supply Plenum Adapters Bulletin 30 20 Page 9 Blower Module Restrictor Plate 1100308 Figure 12 Supply Plenum Adapter Installation four 4 equally spaced sheet metal screws or nails to secure the duct to the supply adapter Then tape around the seam with UL 181A aluminum tape Then wrap the outside of the plenum adapter with the supplied blanket insulation and secure the insulation seams with UL 181A tape Adjust Restrictor Plate to Proper Amperage Figure 13 Restrictor Setting Table 4 Approximate Amperages at Given Airflows MBxxxxL CB Amps 230V 1 MBxxxxL Unit Size multiply by 1 1 if 208V T for more exact airflow use the chart i
51. rom each outlet with a TurboMeter refer to Tech Note 113 How to Measure Outlet Airflow for more in formation Place the TurboMeter against each outlet centered as best possible and record the knots Multip ly the knots by 2 to obtain CFM then sum all the outlets The sum is the total airflow this can be compared to the outlet indicated by the amperage A significant differ ence could indicate duct leakage How to Measure Static Pressure Measure the supply plenum static pressure at least 18 inches 457mm from the unit but before any tee or elbow A distance of between 2 and 3 feet 0 6 to 0 9m is best Use an inclined manometer capable of reading at least 2 5 inches of water column 622 Pa such as Dwyer Instrument s model 109 manometer Be sure to zero the scale and level the manometer A magnehelic gauge that measures up to at least 2 5 inches of water may also be used Use a metal tube typically 4 inch 6mm diameter to measure the static pressure Determine where you want it and cut or punch a small hole in the duct Make the hole the same size as the metal tube to prevent leakage Insert the metal tube 1 inch 25mm so that the tip of the tube is flush to inside wall of the duct and perpendicular to the air stream as shown in Fig 26 Attach the metal tube to the manometer using a rubber hose usually supplied with the manometer Record the pressure Note If the tube is not perpendicular to the air stream th
52. s also provided for an additional double pole double throw DPDT relay for wiring a boiler pump or valve if heat ing with hot water 1 First connect the motor plug to the wiring harness from the control box 2 Then route the anti frost switch lead wires located on the refrigerant coil through the interior of the modules to the control box Connect the leads to terminals 3 and 6 of the Low Voltage Terminal Block ALL DX COILS NEED THE FROST SWITCH 3 Next connect the control wiring per figures 17 through 19 For units with electric duct heaters refer to Bulletin 30 34 Match thermostat anticipator set tings for combined amperage load of all compo nents including electric heater contactors to pre vent damage to thermostat 4 Connect power supply to terminals L1 and L2 on the high voltage terminal block Connect a ground ral _ OUTLET v D AIRFLOW E BRACKET INLET Al E a BLEED VALVE i DRAIN Y a Hot Water Coil BLEED VALVE VENT AIRFLOW BLEED VALVE ILO0054b CVN DRAIN b Chilled Water Coil Figure 16 Water Coil Connections Copyright 2010 Unico Inc Bulletin 30 20 Page 14 wire to equipment grounding on the side of the con trol box near the incoming power opening WARNING Be sure to insulate the unus
53. s or studs are less than 16 inches 406 mm center to center or running the wrong direction it will be neces sary to cut and header the joists ES 1L00037b CNV All dimensions in inches mm Figure 2 Minimum Clearances If installing the unit in an attic avoid placing the unit above a bed The ideal location is above a central hall a closet a bathroom or any normally unoccupied space The unit can also be installed in a closet crawlspace or basement If the local codes allow the unit may be in stalled in the garage provided the ductwork is well sealed especially the return duct Although the unit is not designed for outdoor use it may be located outside provided adequate weather protection is used typically a Cooling Heating Blower Module Module Return Air Adapter 104 ontro Box Band supplied with return air box bow Return Air Duct Plenum UPC 04 xx 1 Adapter UPC 61 xxxx Isolation Pads Typical 10 foot 3 6 m Return Duct Band Secondary Use at least one 90 bend Drain Pan A UPC 20 or 24 q 0 Platform Return Air Box UPC 01 xxxx 1 IL00039c CVS Figure 3 Typical Horizontal Attic Installation Copyright 2010 Unico Inc Bulletin
54. se the size of the liquid line to reduce the pressure drop CAUTION TO MAINTAIN PROPER HEAT PUMP OPERATION DO NOT STRAP THE LIQUID AND SUCTION LINES TOGETHER FOR HEAT PUMP SYSTEMS Superheat Method Do not charge the system based on superheat Superheat measurements should only be used to verify that the expansion valve is working properly If is more than expected please refer to the Technote on troubleshooting expansion valves The superheat should be between 8 to 12 F 4 to 7 C at the indoor coil In some cases particularly for the larger capacity match ups i e 3 ton and 5 ton a superheat of 15 to 18 F 8 to 10 C is satisfactory It is not uncom mon to measure a superheat above 20 to 25 F 11 to 14 C at the condensing unit Be aware that the superheat value is also dependent on the outdoor air temperature At lower air temperatures the superheat will be higher than at higher air tempera tures If the condenser ambient temperature is between 75 and 85 F 24 to 29 C superheat should be approx imately 10 to 12 F 5 to 7 C If the outdoor temperature is between 85 and 105 F 29 to 40 C superheat should be approximately 8 to 10 F 4 to 5 C To measure the superheat use the following 1 Measure and record the suction pressure at the eva porator outlet using an accurate refrigerant gauge If this is not possible measure the pressure at the ser vice port on the suction valve fitting at the condens in
55. stalled Mount the control box using four 4 sheet metal screws as shown in Fig 7 Feed the wires from the anti frost switch through the hole and bushing nearest the side of the unit and connect the leads to low voltage terminals 3 and 6 The motor wiring harness will slip through the other hole Then simply connect the plug on the motor wiring harness For additional information see section on wir ing SN 100332 Figure 7 Mounting the Control Box Secondary Drain Pan Where an overflow of condensate could cause water damage a secondary drain pan MUST BE INSTALLED Place the drain pan on the mounting base platform or angle iron support frame Be sure to allow enough room for the drain line and connection refer to Table 3 The assembled unit should be placed over the secondary drain pan supported by rails with rubber pads for isola tion to raise the unit above the 1 5 inch 38mm sides of the secondary drain pan Table 2 shows the secondary drain pans to be used for horizontally mounted modules For vertical up flow ar rangements that use the cooling module the 2 module drain pans can be used where space permits and the re turn air is entering from the side These pans would be over sized compared to the footprint of the cooling module If a smaller drain pan is necessary it should be fabricated to be at least 12 inch 12 7 mm larger on each side of the bottom module For v
56. t and header at least one joist Center the return air box so the filter frame flange covers all the gaps and make sure the flange is flush against the wall or ceiling Install the return air box against the frame using nails or screws Screw holes are provided in the return air box Use the holes nearest the corners The other holes are for mount ing the filter grille See Fig 14 FRAMING RETURN AIR BOX FILTER FRAME FILTER FILTER GRILLE 100048 Figure 14 Return Air Box and Filter Install filter frame into the return air box using four nails or screws Use the holes furthest from the corners Insert filter and hold in place by rotating metal clips Close grille and secure with clips Refer to Table 5 for correct Return Duct Adapter selec tion Attach the proper return duct adapter to either the Heating or Cooling Module Then attach the return duct to the adapter and to the return air box using the Q bands and Q clips The return air adapter ships with an insulation blanket that must be wrapped around the adapter Tape the seams with UL 181A aluminum tape Table 5 Return Duct Adapter BlowerModule Module BlowerModule Heating Module Cooling Module 4 Cooling Module 4860 UPC 59 4860 UPC 1044860 UPC 1044860 4860 3642 UPC 59 3642 UPC 104 3642 2430 UPC 59 2430 UPC 104 2430 Multiple Returns If more than one return is desired Unico has designed a return plenu
57. ted with ETL Always install a secondary drain pan when an overflow of condensate could cause damage PART NUMBERS This manual does not always include the latest revision letter when referring to UPC part numbers Refer to the latest Price List and Spec Sheets for the current UPC revision letter For example in UPC 00x the x indi cates the latest revision INSTALLATION MANUAL FOR M SERIES MODULAR AIR HANDLER UNITS TABLE OF CONTENTS INTRODUCTION UNPACKING LOCATION UNIT ASSEMBLY Anti Frost Switch Wires Fastening Modules Together EC Motor Temperature Operating Limits Horizontal Installation Vertical Installation Control Box Secondary Drain Pan MOUNTING Horizontal Platform Mounting Horizontal Suspended Mounting Vertical DUCT CONNECTIONS Supply Plenum Return Duct Multiple Returns Condensate Lines Refrigerant Lines Water Connections Coil Cleaning Ventilation Speed Mode STARTUP Sequence of Operation Checking Airflow Charging the System Low Ambient Control Kit R 410A Refrigerant Maintenance Module Configuration Illustrations INTRODUCTION The Unico System is a complete indoor comfort system that includes an indoor air handling unit and small duct system The air handler and duct system were designed to operate together to provide the proper airflow in every installation The conditioned air is supplied through a series of 2 inch ducts as a stream of air that entrains and mixes the room air This proc
58. the system is installed and before charging system check for proper airflow Record the position of the re strictor plate the plenum static pressure and the motor amperage With this information the amount of airflow can be determined Copyright 2010 Unico Inc Bulletin 30 20 Page 22 As a recommended further check on airflow use a ve lometer to measure the airflow from each outlet The most convenient instrument to use is a hand held vane type velocity meter that fits directly over the outlet The Turbo Meter Davis Instruments Catalog No DS105107 or equivalent meter will give a direct LED readout on the Knots FPM x 100 setting when multiplied by 2 gives the CFM of the outlet within an accuracy of 10 Multiply knots by 0 94 to obtain L s Refer to Tech note 113 for more information By measuring and totaling the airflow of all outlets the total airflow of the system can be closely approximated and provide a crosscheck for the airflow determined from the motor amperage using the airflow amperage table that is shipped with the Blower module Note These tables are for the specific mo tor installed in each blower module Be sure the table used applies to the correct model number that is shown on the table Use Table 7 to correct the airflow Check Static Pressure Measure the external static pressure see the following section in the supply plenum at least two feet 610 mm from the unit and verify t
59. tion anytime the speed switch is turned in the ON position To turn on or off this feature at the thermostat refer to the supplementary wiring diagrams for instruc tions located near the end of this document Ventilation Soeed Mode The Unico System 15 factory configured to energize the fan at full speed whenever there is a call for heat or cool or when the fan switch is set to ON The unit can be set for constant ventilation at the air handler whenever the fan switch is in the AUTO position and there is no call for heat or cool There is a variable speed switch on con trol box which can be adjusted for the desired speed The variable speed control is set to the OFF setting at the factory To enable this feature we recommend setting it to the lowest speed fully clockwise In this configuration the ventilation speed can only be adjusted or turned off or on using this switch This can be inconvenient if the unit is not easily accessible To allow the user to turn the ventilation speed mode on or off at the thermostat using the FAN switch the factory wiring can be modified as shown in figures 22 to 25 depending on the configuration To accomplish this two wires inside the control box must be moved as described on the wiring schematics Copyright 2010 Unico Inc Page 15 Bulletin 30 20 NMOHS Z SSv 10 O3N SSY19 93N AHOLOVJ HOOHS VOIHLIO3 I3 HLV3G HO AYNFN
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