INSTALLATION MANUAL M1218 FAN COIL
Contents
1. 2010 Unico Inc hooks as applicable to attach the chains or cables to the unit and the ceiling Place the unit inside of the secondary drain pan as you would for platform support with the angle iron supports lengthwise under the secondary drain pan Level the unit by adjusting the length of the chains or cables If using the alternative method hang the secondary drain pan from the unit using self tapping screws and metal straps or wires Adjust the straps or wires to pitch the secondary drain pan toward the drain connection Ceiling Mounting If desired the unit can be mounted flush to the ceiling see Fig 7 using the optional mounting rails UPC 95 Remove top screws from both sides of the unit Align holes on mounting rails with the holes on the unit Fasten mounting rails to the unit with the screws that were removed earlier Attach unit to a structural member Refer to Fig 8 for the screw hole pattern Suspend secondary drain pain from the unit with metal straps or wires 4 Chain or Cable Unit Isolation Pad Secondary Drain Pan 2 Angle Iron Figure 6 Typical Horizontal Suspension Mounting Joist Ceiling Mounting Rails Unit Metal Straps or Wires Secondary Drain Pan 1L00164 CV5 Figure 7 Typical Ceiling Mounting Vertical Rail Mounting The unit can only be mounted in the2. The following procedure is only valid for charging the system during the cooling mode To check for proper charge record the refrigerant pressures 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 is 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 care fully leak tested and evacuated release the R22 operating charge in the condensing unit The system is now ready for refrigerant charge adjustment 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
3. unit is properly grounded Installation should be in accordance with all local codes and regulations and with the National Fire Protection Association and Underwriters Laboratories applicable standards and 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 local codes and regulations Condensate piping should be installed in accordance with governing code 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 UPC 00A where A is the latest revision INTRODUCTION The Unico System is a complete indoor comfort system that includes an indoor fan coil unit and small duct system The fan coil unit 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 two inch diameter ducts as a stream of air that entrains and mixes with the room air This process of aspiration produces a more even temperature distribution in the room than a conventional system l CERTIFIED TO UL STD 1995 C US CONFORMS TO CAN CSA STD ES C22 2 NO 236 81037 Copyright 2010 Unico Inc Bulletin 30 10
4. LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK WIRING LEGEND FACTORY FIELD NEC CLASS 1 FIELD NEC CLASS 2 Figure 18 M1218 Electrical Wiring Diagram Copyright 2010 Unico Inc I05 amp 0 CVS Bulletin 30 10 Page 9 Match thermostat anticipator settings for combined amperage load of all components including electric heater contactors to prevent damage to thermostat 2 Connect power supply to terminals L1 and L2 on the high voltage terminal block Connect a ground wire to equipment grounding lug located inside of the control box near the incoming power opening WARNING INSULATE THE UNUSED TRANSFORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK BE SURE TO The low voltage transformer is factory wired for a primary voltage of 230V If power supply is 208V remove ORANGE lead from L2 terminal and connect TYPICAL THERMOSTAT UNICO SYSTEM AIR HANDLER OUTDOOR CONDENSING UNIT COMPRESSOR COMMON Figure 19 Control Wiring Diagram for UNico SYSTEM Cooling Only Applications RED lead to L2 Insulate the connector on the unused wire lead Hydronic Heating Hot Water Coil Wiring A normal heat cool thermostat will not energize the indoor blower during the heating cycle therefore use either use a electric furnace thermostat or installed a low voltage double throw double pole DPDT relay as shown in Fig 21 e g Honeywell R8222N1011 relay or equal If an
5. Page 2 Heating Onl Blower Cabinet Hot Water Coil Horizontal Flow Cooling Onl Blower Cabinet Cooling Coil Heating and Cooling Blower Cabinet Hot water Coil Cooling Coil n i L J m Vertical Up Flow Figure 1 Unit Arrangement The Unico M1218 Fan Coil unit is a single packaged unit The cooling and heating coils are contained within the same cabinet The unit can be mounted in a vertical upflow or horizontal flow configuration The coils can be combined as a heating only cooling only or heating and cooling fan coil unit See Fig 1 The unit is available in one size 38 in L x 20 in W x 12 in H 965 mm x 508 mm x 305 mm The heating only system includes the blower motor and a hot water coil The cooling only system includes the blower motor and a cooling coil For the heating and cooling system both coils are provided The cooling coil may be a refrigerant coil a heat pump coil or a chilled water coil The electrical panel is located inside of the cabinet UNPACKING All units are inspected prior to sh
6. build a frame to hold the return air box Otherwise it will be necessary to construct a frame around the opening 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 Holes are provided in the return air box Use the four 4 14 inch 6 4 mm holes The other holes are for mounting the filter grille See Fig 11 Install filter frame into the return air box using four 4 nails FILTER FRAME FILTER FILTER GRILLE IL00153 CV5 Figure 11 Return Air Box and Filter or screws Insert filter and hold in place by rotating metal clips Close grille and secure with clips Connect the return air adapter to the unit using sheet metal screws Then attach the return duct to the adapter and to the return air box using the supplied band Tape the seams with UL 181B duct tape PIPING All piping must be in accordance with all local codes and ordinances Condensate Lines The primary drain pan condensate connection is a 1 2 inch 13 mm female pipe thread fitting and the secondary drain pan connection is a 3 4 inch 19 mm PVC socket fitting Copyright 2010 Unico Inc Elevate the unit so the condensate lines are pitched at least 14 inch per lineal foot 20 mm per meter Trap the condensate line near the unit as shown in Figure 12 In some cases it may be necessary to wrap the co
7. 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 temperatures 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 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 condensing unit Typically a low ambient control is necessary when operating the unit at outdoor temperatures below 80 F 26 6 C These controls come in different configurations such as the Hoffman Controls Corp series 800AA head pressure control This control modulates the outdoor blower to maintain 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 Montreal in response to the growing pressure
8. 50 95 295 0 14 1120 100 317 0 105 341 0 110 365 0 30 1780 115 391 0 32 1880 120 418 0 34 1980 125 447 0 36 2090 130 477 0 38 2200 40 2320 42 2440 44 2560 46 2690 48 2820 50 2960 52 3100 54 3250 Copyright 2010 Unico Inc Bulletin 30 10 Page 15 Appendix A Hot Water Coil Performance Entering We Airflow SCFM m s Water Elowrata 200 0 09 300 0 14 400 0 19 Temperature Capacity Capacity Capacity oF oC GPM MBH Kw MBH KW MBH 12 48 9 13 54 4 14 60 9 2 69 9 57 21 23 37 38 16 71 1 17 16 7 Minimum Number of Outlets Oo A NIO Oo FR NO Oo BR MIO DD FR MFO Oo FR MFO Oo SF To 0 0 0 0 0 CO Entering dae Airflow SCFM m s Water Elowrata 200 0 09 300 0 14 400 0 19 Temperature Capacity Capacity Capacity WPD F MBH KW SHR MBH KW SHR MBH KW SHR ft water KPa 13 6 0 59 17 2 14 4 0 58 18 9 14 9 0 58 11 8 0 60 12 6 0 59 13 0 0 59 10 0 0 62 10 6 0 61 11 0 0 61 0 67 10 2 0 66 11 1 0 65 8 8 6 0 1 75 0 76 0 80 0 84 1 8 6 2 1 83 0 74 0 78 0 81 3 4 6 4 1 88 0 73 0 77 0 80 5 3 MmmumNumberoOuets 6 3 38 D oo 55 Copyright 2010 Unico Inc Bulletin 30 10 Page 16 Joo Appendix C Engineering Specifications Unico Part No Construction Dimensions inch mm 12H x 20 W x 38 L 31 x 51 x 97 Cabinet Type Galvanized or Painted P option Insu
9. Bulletin 30 10 Nov 2010 The Unico Systenr INSTALLATION MANUAL M1218 FAN COIL NOTICE TO INSTALLER AND EQUIPMENT OWNER RETAIN THIS MANUAL AT THE JOB 1100159 CV5 TABLE OF CONTENTS INTRODUCTION UNPACKING LOCATION SECONDARY DRAIN PAN MOUNTING Horizontal Platform Horizontal Suspended Vertical DUCT CONNECTION Supply Plenum Return Duct PIPING Condensate Lines Refrigerant Lines Expansion Valve Water Connections WIRING CHARGING AND STARTUP Sequence of Operation Fan Speed Checking Airflow Charging a Cooling System Low Ambient Control Kit Charging a Heat Pump System Mild Weather Kit APPENDIX A Hot Water Coil Capacities APPENDIX B Chilled Water Coil Capacities APPENDIX C Specifications General The information on the following pages is to help the installer save time provide the best possible installation and insure continuous trouble free operation Scope These instructions apply to the Unico M1218 Fan Coil unit Installation instructions for the air distribution system are covered in other bulletins Before beginning any installation a detailed system layout must be done in accordance with Bulletin 40 40 System Sizing and Layout bulletin SUFFICIENT 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
10. aqua stat is not used install a wire from terminal 5 of the low voltage block to terminal 3 of the relay as shown in Fig 21 TYPICAL HEAT PUMP THERMOSTAT UNICO SYSTEM OUTDOOR AIR HANDLER CONDENSING UNIT DEFROST HEAT C 0 9 COMPRESSOR REV VALVE COOLING REV VALVE w POWER te PowER REV VALVE HEATING HY COMPRESSOR amp COMMON COMMON EMER HEAT AUX HEAT G Gi mi 69 9 Gi 9 AUX HEAT WIRING DIAGRAM AS SHOWN IS FOR A REVERSING VALVE THAT IS EE IN COOLING MODE WHEN VALVE IS ENRGIZED IN HEATING MODE USE TERMINAL ON THE THERMOSTAT INSTEAD OF THE O TERMINAL Figure 20 Control Wiring Diagram for Unico 1100174 CVS CONTROL WIRING DIAGRAM FOR COOLING ONLY UNICO SYSTEM WITH HY DRONIC HEAT WITH ISOLATED BOILER PUMP SWITCH THERMOSTA Rioneywell T87F Thermostat with Q539A e FAN 5 Yo HEAT 9i DPDT RELAY vise send a r Steveco 90 340 re or equal UNICO peu N COMPRESSOR Ton ibis i LI ge BOILER OR 1 POWER EIN GE j i l 1 l d hi i D 1 7 LI LI 1 e e egi s m REC OUTDOOR CONDENSING UNIT Ra POWER ei CN COMMON Oi AQUASTAT Figure 21 Control Wiring Diagram for Cooling Only Unico System with Hydronic Heat with Isolated Boiler Pump Switch Charging and Startup Sequence of Operation The sequence of operation depends greatly on the options installed and type of control thermostat us
11. be determined As a recommended further check on airflow use a velometer to measure the CFM 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 By measuring and totaling the CFM 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 and Table 4 Use Table 5 to help troubleshoot airflow problems Bulletin 30 10 Page 11 Static Pressure Measure the external static pressure see the following section in the supply plenum at least two feet 0 6 m from the unit and verify that it is within the allowable range The plenum static pressure should be 1 4 to 1 6 inches of water column 350 to 400 Pa It is not necessary to measure the return duct static pressure unless it was field fabricated The maximum return static pressure including filters should be 0 15 inches of water column 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 pressure drop For example If the supply static pressure is measured to be 1 6 inches w c and the return syst
12. be taken to assure proper drain line pitch 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 l inch 13 mm plywood and stud frame Table 3 Lists the maximum horizontal drain line run for various framing materials and still provide adequate drainage Table 2 Horizontal Distance of Drain Piping for Different Framing Materials 34 10 42 13 Max Horizontal Run ft m 18 5 The platform size should be a minimum of 24 x 42 inches 610 x 1066 mm 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 high enough in the drain pan to allow for primary drain line condensate connection Rafter Joist or Floor HE DG See Table 3 Figure 5 Typical Platform Installation Il0O147 CV5 Horizontal Suspended Mounting The unit can also be suspended from the ceiling or rafters The preferred method is to support the unit and the secondary drain pan from underneath with angle iron supports see Fig 6 As an alternative the unit can be hung with the mounting rails CAUTION DO NOT HANG UNIT FROM TOP OF CABINET IF NOT USING MOUNTING RAILS TO AVOID DAMAGING THE EQUIPMENT Use either four 4 chains or steel cables with 80 lbs 36 kg test strength to hang the unit Use eyebolts and J Copyright
13. d the return air adapter refer to Fig 4 Multiple returns or extra long returns are possible so long as the maximum pressure loss is not exceeded The return system is designed for a maximum static pressure drop of 0 15 inches of water 37 Pa including the filter The return duct should have at least one 90 degree bend between the unit and filter box to reduce sound transmission directly from the unit Although Unico only supplies a single return system the return system can be redesigned for multiple returns The return duct system is a conventional duct design not high velocity therefore the return system may be different Copyright 2010 Unico Inc Bulletin 30 10 Page 6 provided the static pressure does not exceed 0 15 inches of water column and there is some form of sound attenuation Generally this means sizing the duct for a pressure loss of 0 05 inches of water column at the required airflow and sizing the filter for a pressure drop of 0 10 inches of water column at the required airflow Sound attenuation can be accomplished with fabricated duct board lined sheet metal or acoustical flex Part number UPC 04 1218 For best attenuation always have at least one 90 degree bend to eliminate direct line of site from the unit to the return opening To install the return filter and grille cut an opening for the return box as specified in Table 1 If the joists or studs are on 16 inch 410 mm centers there is no need to
14. ed Most thermostats have a fan AUTO ON switch When the fan switch is set to ON the G circuit is closed and the blower relay is energized The indoor blower starts after about a 20 second delay The following paragraphs describe 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 thermo stat calls for cooling the Y and the G 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 operating 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 reversing valve solenoid Refer to the heat pump manufacturer s instructions to see which mode the solenoid needs to be energized whether in heating or cooling When the th
15. em 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 Motor Amperage Remove the control panel and measure the current with an amp meter and compare to Table 4 How to Measure Static Pressure Measure the supply plenum static pressure at least 24 inches 610 mm from the unit but before any tee or elbow A distance of between 2 and 3 feet 0 6 to 0 9 m 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 Metal Tube w Marks Static Pressure Reading When bubbles just stop IL00053 CV5 Figure 23 Glass Bubble Manometer Table 5 Airflow Troubleshooting Chart Problem Low Static and Low Voltage Low Amperage Blower Wheel not aligned properly Manometer Measuring Tube Plenum Inside of Plenum End must be flush here AIRFLOW IL00051 CV5 Figure 22 Measuring Plenum Static Pressure 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 1 4 inch 6 mm 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 one inch 25 mm so that the tip of the tube is flush
16. equalizer line and distributor inlet 2 Connect valve to distributor and tighten flare nut 3 Connect external equalizer line and tighten flare nut 4 Connect to the outlet the 3 8 9 5 mm OD copper refrigerant fitting Make sure the flare nut is tight 5 After all lines have been connected pressure check the connections by charging the system with 150 psig of dry nitrogen and check for leaks at all connections Locate the bulb at the 12 O clock position on a horizontal straight section of the 5 8 16 mm suction line see Fig 15 Attach the bulb to the tubing with the two straps that are provided For satisfactory expansion valve control good thermal contact between the bulb and the suction line is essential Distributor Extemal Equalizer Line Expansion Valve Seal Plate Liquid Line Suction Line Bulb Service Port oorzonevs Equalizer line port Figure 15 Expansion Valve Location CAULK TOP amp BOTTOM AIRFLOW 6a CVs INLET Figure 16 Hot Water Coil Connection Copyright 2010 Unico Inc Bulletin 30 10 Page 8 Water Connections If you are installing the hot water coil remove the side coil access panel Slide the coil into the cabinet if not already installed at the factory and reinstall the door panel After removing plugs in the inlet and outlet holes caulk around connections to prevent leakage Pump and pipe sizing should be based on proper flow rate Re
17. ermostat is satisfied the 24 V signals open and the outdoor unit stops The indoor blower continues to operate for about 40 seconds then stops The system is now off Heating Cycle Heat Pump Setting the thermostat to HEATING will automatically switch the reversing valve Copyright 2010 Unico Inc Bulletin 30 10 Page 10 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 G circuits are closed sending a 24 V signal to the compressor contactor in the outdoor unit and the fan relay in the indoor unit This starts the indoor blower and the outdoor compressor and blower There is a time delay of about 20 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 electric heat 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 open and the outdoor unit stops The indoor blower continues to operate for about 40 seconds then stops The system is now off Heating Cyc
18. fer to Appendix A for water coil capacities based on flow rate All water connections are 5 8 inches OD 16 mm sweat connections Sweat the water connections then fill the system Install a vent valve at the highest point and a drain valve at the lowest point of the water system refer to Fig 17 Fill and bleed the air from the system If unit is in an unconditioned space care must be taken to prevent the water from freezing Use a glycol water antifreeze solution with a freezing point below the coldest temperature expected As an alternate to an anti freeze solution the water can be continuously circulated to prevent freezing If the coil will not be used for an extended period of time during cold temperatures drain the system then flush with a glycol solution Wiring WARNING DISCONNECT ELECTRICAL SUPPLY BEFORE WIRING UNIT TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK CONNECT All electrical wiring must comply with all local codes and ordinances Make electrical connection in accordance with the wiring diagram shown in Fig 18 Use a separate 1 ph 230 208V 60 50 Hz power supply with a 15 amp fuse or breaker and appropriate wire gauge per local code zD230VDS NOT OVER 15 AMP FUSE TOFUS The wiring diagrams in this instruction manual are for a cooling only system heat pump system without electric heat or cooling with a hot water coil Separate wiring instructions for electric heating wi
19. in cooling mode If this is not possible because of low outdoor temperatures charge the system in the heating mode but return later when the weather is warmer before the system is switched to cooling Subcooling Method Many condensing unit manufacturers publish the amount of subcooling that the condenser will produce Follow their instructions to charge the unit Typical subcooling values will be between 8 and 15 F 5 to 9 C The unit should ALWAYS have some amount of subcooling To be sure there is enough subcooling especially if the unit is in a hot attic check the liquid line sight glass near the evaporator for bubbles or measure the refrigerant liquid line pressure and temperature AT THE EVAPORATOR Copyright 2010 Unico Inc To measure subcooling 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 6 2 Measure and record the liquid line temperature using an accurate metal or glass thermometer or thermocouple Tape or strap the sensor firmly against the surface of the liquid line and cover with insulation 3 Determine the subcooling with the following equation SATURATED TEMPERATURE LIQUID LINE TEMPERATURE SUBCOOLING If the subcooling temperature at the condenser is low the system is undercharged If it is high the system is overcharged and some refrigerant must be re
20. ipping and are carefully packaged in individual cartons Inspect all cartons prior to unpacking Notify carrier of any damage Open the carton to remove the unit Inspect unit for visible CARDBOARD SUPPORTS 190176 CVE Figure 2 Location of Motor Shipping Supports Copyright 2010 Unico Inc 4 1L00148 CV5 signs of concealed damage and notify carrier of any such damage All materials are sold FOB Factory and it is the responsibility of the consignee to file any claims with the delivering carrier for materials received in a damaged condition Open the blower access panel to remove the motor shipping support See Fig 2 The expansion valve is shipped loose and is located in the coil compartment near the connections MOUNTING The unit comes factory ready for horizontal or vertical airflow applications see Fig 1 and may be mounted to a structure using the optional mounting rails UPC 95 LOCATION Locate the air handler to minimize the number of plenum elbows and fittings while keeping the supply duct runs as short as possible See Bulletin 40 30 Component Layout The fully insulated cabinet allows installation with zer
21. ir box and filter near the unit allowing at least one 90 bend in the return duct for proper acoustical performance Fig 4 shows a typical horizontal attic installation Plenum Control Adapter Panel Coolin UPC 61 1218 Blower Gen Chilled Hot water N N Cabinet water coil coil water o b d water lines lines S a f E j Se a Tat S om DUT ae i v iN T IN LI Isolation SE Ps 1 D a en RA AR Se hg My AUR Hy hg ARN NN RN d ANA Sj Secondary pa M SESS TT SE Drain Pan BESSA UPC 94 d t E E Platform Figure 4 Typical Horizontal Attic Installation M1218 Bulletin 30 10 Page 3 The standard return duct is 10 feet 3 m in length so it may have to be cut to avoid bunching if the distance to the unit is significantly less than 100 inches If needed up to two return ducts can be coupled to make a 20 ft 6 m duct The minimum length should be 6 feet 2 m When given a choice maximize the distance and make at least one 90 bend for the best sound attenuation Each unit is designed to fit into a small space where a conventional unit could not be used The 12 in height allows the unit to fit through joists or studs spaced at least 16 inches 406 mm on center If no access is provided an opening must be cut It is suggested to use the opening required for the return air box especially in an attic installation The opening size for the return air box is listed in Table 1 If the joist
22. lation 1 inch 2 5 mm coated fiberglass duct liner Drain pan Stainless Steel Drain pan connection 1 2 inch FPT Standard Return Duct ID in cm 12 30 5 Standard Plenum ID in cm 7 0 17 8 Electrical Type 1 ph 60 50 Hz 230 208V Power Input W 310 Fan Relay Snap acting with inherent time delay A00056 G02 Transformer 50 VA 230 208V 24V A00057 G02 Motor 2 speed A00974 001 3 speed A00331 001 Size hp kW 1 3 0 25 Running Speed rated airflow 1625 825 RPM 1700 1550 1350 FLA 1 5 1 9 RLA Refer to Amperage Chart Bearing Type Permanently Lubricated Ball Blower Wheel A00757 001 Airflow CFM m s 200 094 300 142 400 189 450 212 Static Pressure in wc Pa 1 80 448 1 50 373 1 00 249 0 70 174 Type SISW Forward Curved Nom Diameter inch cm 9 5 24 Width inch cm 1 5 3 8 Refrigerant Coil AC or HP option A00326 001 Nominal Capacity tons kW 1 to 1 5 3 5 to 5 3 Rated Airflow CFM m s 450 0 212 Min Airflow CFM ton m s kW 200 0 027 Refrigerant Type R 410a Face Area ft m 1 167 0 108 Number of Rows 6 Number of Circuits 3 Fin Density fins in fins cm 15 6 Fin Type and pattern in cm Corrugated 1 x 0 625 2 540 x 1 588 Tube Diameter in cm 3 8 0 953 Tube Type Rifled Expansion Device AC option TXV with Bleed Port A00365 002 Expansion Device HP option TXV with Bleed Port and Internal Check Valve A00366 002 Liquid Line Connection 3 8 953 Sucti
23. le Electric Heat 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 cycles 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 open 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 G circuit on heating Heating Cycle Hydronic Heat When the thermostat calls for heating the W circuit is closed sending a 24 V signal to the field installed heating relay This relay closes two circuits One completes the boiler circuit which either opens a valve or starts a pump The other completes the fan relay circuit energizing the blower motor relay and starting the blower after a 20 second delay If an aquastat is utilized the fan relay circuit will remain open until the aquastat is satisfied When the thermostat is satisfied the 24 V signal to the heat relay opens and the pump or valve circuit opens which stops the pump or closes a valve The fan circuit opens and de energizes the fan relay After ab
24. ll ship with that the electric duct heater 1 Connect the control wiring per Fig 19 for cooling only application Fig 20 for NOTES Unico System rest 2 COMMON amp MER M1218 POWER DRAIN BOILER WATER HEATER TO BOILER FROM PUMP BOILER lt lt 1100176 Cv5 Figure 17 Water Piping Schematic FOR COOLING ONLY INSTALLATIONS TYPICAL TYPICAL OMIT ITEMS MARKED OUTDOOR THERMOSTAT REV VALVE SEE NOTE 1 HEATING x REV VALVE COOLING SECTION BEROST gu e c COMMON Kaes POWER REV VALVE Y COMPRESSOR ANTI FROST CONTROL BYPASS AzLAY HEAT PUMPS ONI Y SEE NOTE 3 EQUIPT GROUND ANTI FROST NTROL SEE NOTE 4 MOTOR SEE NOTE 5 icati IF REVERSING VALVE IS ENERGIZED ON HEATING CONNECT TERMINAL heat pump applications or Fig 2 for unc hc cooling with a hot water coil Refer to IF MEASURED SUPPLY VOLTAGE IS 208V OR LESS REMOVE ORANGE REMOVE TAPE FROM AED UNCONNECTED TRANSFORMER LEAD AND Installation Instructions for Electric SECURE TO TERMINAL INSULATE THE LEAD ON THE ORANGE WIRE gt ANTI FROST CONTROL BYPASS RELAY IS USED FOR HEAT PUMP VER Duct Heaters for wiring instructions for HIDE auxiliary heaters ANTI FROST CONTROL IS USED ONLY WITH REFRIGERANT COILS THE MOTOR MAY BE 2 OR 3 SPEED WARNING BE SURE TO INSULATE THE UNUSED TRANSFORMER
25. moved and collected in an empty refrigerant container Do not vent the refrigerant it is a violation of federal law In some cases such as in a hot attic the liquid line will pick up heat and lose its subcooling This will be apparent if the subcooling 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 increase 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 uncommon 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 temperatures If the condenser ambient temperature is between 75 and 85 F 24 to 29 C s
26. ndensate line near the unit with insulation to prevent water from condensing on the outside of the pipe In some climates or locations it may be necessary to protect trap from freezing in the winter Pitch inch per foot 2 cm per m IL00154a CV5 Optional Condensate U TRAP A00924 Figure 12 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 terminate 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 An alternative method of notifying the homeowner about a leakage problem is to use a paper fuse and micro switch See Fig 13 Install a micro switch upside down on the side of the secondary drain pan Making sure that the switch is open Next sandwich a paper fuse between the switch and the bottom of the drain pan so that the switch is closed When water is present in the secondary drain pan the fuse will dissolve and the switch will open causing the outside unit to shut down until it is serviced Also available is the Unico Condensate U Trap which features a clear trap that is easy to visually inspect for clogs The U Trap is designed for the Unico System with a 2 5 inch 64mm deep trap to handle the higher static pres
27. o clearance to the top bottom or sides of the unit However clearance must be provided for servicing which is dependent on how the unit is installed Servicing of the blower motor assembly and coils can be performed in three different ways 1 The complete top panel which is attached to blower motor assembly can be removed To do this the motor leads must be disconnected in the control compartment 2 For side access remove the control panel cooling coil panel or heating panel which are located on the same side as the refrigerant drain and water connections 457 top clearence for service 1 25 Minimum A Supply plenum Side View Air Flow Secondary Drain P an l i Air Flow 1 25 Minimum Supply Plenum Top View Return Duct et E eene 24 610 side clearance for service i Suspended Installation Side View Supply plenum Air Flow 18 457 bottom clearance for service All dimensions in inches mm 1L00149 CV5 Figure 3 Minimum Clearances 3 Where the unit is suspended or mounted on the wall using the mounting rails the panel below the blower motor assembly can be removed for servicing In this case access to the coils must be from the side access panels See Fig 3 Position the return a
28. on Connection OD in cm 5 8 1 588 Hot Water Coil HW option HW 1218 Fluid Type Water or Glycol Water Solution Face Area ft m 1 0 0 093 Number of Rows 4 Number of Circuits 4 Fin Density fins in fins cm 10 4 Fin Type and pattern in cm Raised Lance 1 x 866 2 540 x 2 200 Tube Diameter in cm 3 8 953 Connection OD SWT in cm 5 8 1 587 Chilled Water Coil HW option A00397 G01 Fluid Type Face Area ft m Water or Glycol Water Solution 1 167 0 108 Number of Rows 6 Number of Circuits 6 Fin Density fins in fins cm 15 6 Fin Type and pattern in cm Corrugated 1 x 0 625 2 540 x 1 588 Tube Diameter in cm 3 8 953 Connection OD SWT in cm 5 8 1 587 The highest speed is not used Static pressure across unit without hot water coil using 6 inch ID plenum Motor speed set to high for 2 speed motors and medium for motors with 3 speeds Static pressure will be greater when using 7 inch ID plenum Copyright 2010 Unico Inc
29. out 40 seconds the blower stops Copyright 2010 Unico Inc Fan Speed The standard motor has 3 speeds but it operates as a one speed motor Select the speed which achieves at least 300 CFM 142 L s More air is generally not a problem unless the air flow from the outlets exceeds 40 CFM 19 L s If this is the case simply choose a lower speed making sure the minimum airflow through the unit is maintained The unit is factory set to use the medium speed with the standard motor The optional 2 speed motor is available with the Unico ACB Advanced Control Board For more information on this feature refer to Bulletin 30 38 Table 4 Motor Amperage xm 0 Airflow Amperage 230V Q 230V High Medium Ms Vs Speed Speed E 3 Speed Motor Standard Fes i wapa MD NOM Low speed for the optional 2 Speed motor produces half the high speed airflow 1 0 amp amp 230V 2 Speed Motor Optional Check for the proper airflow by measuring the amperage and compare to Table 4 For hot water systems refer to Appendix A for minimum airflow Checking Airflow CAUTION DO NOT OPERATE BLOWER WITH FREE DISCHARGE OR LOW STATIC PRESSURES BELOW 1 INCH WC 250 Pa TO PREVENT MOTOR FROM OVERLOAD ING After the system is installed and before charging system check for proper airflow Record the plenum static pressure and the motor amperage and voltage With this information the amount of airflow can
30. s or studs are significantly less than 16 inches 406 mm center to center or running the wrong direction it would be necessary to cut and header the joists Table 1 Return Air Box Opening Return Air Box Part No Ze of Opening Inches mm 14 3 8 x 20 365 x 521 1218 UPC 01 1218 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 2 The unit should be placed over the secondary drain pan Use rubber pads for isolation to raise the unit high enough in the secondary drain pan for the drain line to clear the side Table 1 Secondary Drain Pan Dimensions inches mm 42 x 24 M1218 UPC 94 1066 x 610 T NOTE The drain fitting extends 7 8 inch 22 mm beyond this dimension pm Return Air Adapter On UPC 104 1218 __ Q Band and Q Clip H 1 i _ Return Air Duct LV VW UPC 04 1218 For 10 foot 3 6 m Return Duct Do not exceed 100 inches 2 5 m Return Air Box ze UPC 01 1218 ILOO150a cvx Copyright 2010 Unico Inc Bulletin 30 10 Page 4 Horizontal Platform Mounting Mount the unit horizontally when vertical height is limited such as in an attic or crawl space It is easiest to mount the unit on a platform but care must
31. sures The U Traps also feature easy to remove clean out caps and incorporate to tees to accommodate any piping arrangement Part No A00924 Refrigerant Connections CAUTION WHEN BRAZING PURGE WITH NITROGEN GAS TO PREVENT THE FORMATION OF OXIDES Switch Paper Fuse 1100156 Cv5 Location of Paper Fuse Indoor Terminal Block 1 2 3 4 5 B 66660606 Condenser Switch IIl00157 CNV Figure 13 Wiring Diagram for Paper Fuse The refrigerant lines are copper sweat connections The liquid line is 3 8 inch 9 5 mm OD and the suction line 1s 5 8 inch 16 mm OD Refer to the condensing unit manufacturer s instruction for proper line sizing information based on distance from condenser Install a liquid line filter drier as close to the coil as possible to protect the evaporator from foreign object debris For troubleshooting purposes especially 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 see Fig 14 T GAS SUCTION EVAPORATOR COIL LIQ lt FROM CONDERSER i 1100161 Cv5 AIR Figure 14 Refrigeration Schematic Expansion Valve The expansion valve is shipped loose inside the unit in the blower section Install the valve inside the unit as shown in Fig 15 Use the following steps when installing Bulletin 30 10 Page 7 1 Remove plastic caps to external
32. te bulletin for the installation of the ductwork A 6 in plenum can be used so long as a 7 in duct 1s attached to the unit and is then reduced at least 4 ft from the unit To attach the plenum adapter to the unit align the holes on the adapter with the holes located around the supply outlet on the unit Mount the adapter with six 6 sheet metal screws See Figure 10 Attach the plenum to the adapter by inserting it over the collar Use three 3 or four 4 equally spaced sheet metal screws to secure the duct to the collar and then tape around the seam with UL 181A aluminum tape Then wrap the 1 in fiberglass blanket duct insulation around the adapter and seal with UL 181A aluminum tape Blower Cabinet Plenum Adapter Pi Gef Insulation Wrap IL00155 CV5 Figure 10 Plenum Adapter Installation The supply plenum also can be square or rectangular The inside dimensions of the duct must provide a minimum of 30 sq in 194 sq cm of flow area e g 5 X 6 in 4 x 7 1 2 in 125 x 150 100 x 190 mm The square 6 x 6 in 165 x 165 mm fiberglass plenum that is available from Unico along with matching tees elbows and end caps can also be utilized However it is recommended that the duct be a minimum of 4 inches 102 mm in height for the takeoff to mount properly Return Duct The Unico return air system has a single return that includes the return air box with filter the acoustical flex return duct an
33. to inside wall of the duct and perpendicular to the air stream as shown in Fig 22 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 the reading will be in error You will get a higher reading if the tube is angled toward the air stream 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 23 Blocked filters restriction in return duct Clear restriction Check with local utility Center wheel inside of inlet ring Position on shaft for 1 8 inch 3 mm clearance from inlet ring Low static Large number of outlets or open duct Add balancing orifices to outlets check for missing high amperage end caps or separated plenum High Static Low Amperage Restrictive duct system Add outlets add splitter vane in tee reduce the number of tees and elbows in plenum increase plenum size to 9 equivalent Copyright 2010 Unico Inc Bulletin 30 10 Page 12 Charging a Cooling System DO NOT VENT REFRIGERANT TO THE ATMOSPHERE It is a violation of federal law and in some cases local ordinances Always use a refrigerant recovery or recycling device If charging a heat pump refer to Bulletin 30 24 Instructions for M Series Modular Heat Pump Systems
34. 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 Chlorofluorocarbons 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 Protocols next phase out targets are hydrochlorofluorocarbons HCFCs including R 22 the primary refrigerant in residential heating amp air conditioning products The 1990 Clean Air Act in conjunction with the Montreal 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 used The phase out schedule is timed so that R 22 is available for expected lifespan of the R 22 equipment Charging a Heat Pump System Charging in Cooling Mode Charging a heat pump by its nature 1s more difficult than a cooling only refrigerant system Quite often the ideal charge for cooling is different than the ideal charge for heating making the system much more sensitive to the amount of charge In some cases the compressor will trip on high head pressure during the heating mode because it is overcharged if the system was charged during cooling Likewise the system may cycle on the anti frost control beca
35. uperheat should be approximately 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 Bulletin 30 10 Page 13 To measure the superheat use the following 1 Measure and record the suction pressure at the evaporator outlet using an accurate refrigerant gauge If this is not possible measure the pressure at the service port on the suction valve fitting at the condensing unit and add the estimated pressure loss in the suction line between the condensing unit and evaporator Record the corresponding saturation temperature for this pressure see Table 6 2 Measure the suction line temperature at the evaporator outlet using an accurate metal or glass thermometer 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
36. ure system usually about 40 to 50 psig higher It is this higher English units SI units pressure that produces a warmer air temperature preventing psig kPa gauge cold blow where the house is being heated with an air E R 410A de R 410A stream that feels cold 0 48 4 18 330 Some outdoor heat pump units include a manual high 2 zum di 347 pressure switch It is important that the system be operated S SE 16 363 at pressures below the trip pressure of the high pressure 2 222 15 380 switch to avoid nuisance shut downs If this occurs use a B av 14 398 high head kit as described below 10 60624 13 416 12 65 4 Using a High Head Kit Mild Weather Kit When any 4 e e Lists heat pump is operated during mild weather temperatures 16 718 T 453 above 50 F 10 C the compressor may trip out on the 18 751 10 473 high pressure limit The Unico System is particularly 20 785 9 493 sensitive to this since it operates at a higher pressure 25 EE 8 513 To overcome this problem install a mild weather kit UPC 24 85 7 zi oo 65 to cycle the outdoor fan based on the compressor 26 89 4 i 222 discharge pressure However be sure this control is 28 93 2 9 578 compatible with the outdoor heat pump section being used 30 97 2 A 601 32 101 0 624 34 105 0 2 648 36 110 0 1 673 38 114 0 0 698 40 119 0 1 723 42 123 0 2 750 44 128 0 3 777 46 133 0 4 804 48 138 0 5 833 50 143 0 6 861 55 156 0 7 891 60 170 0 8 922 9 953 10 984 90 274 0 12 10
37. use of a low refrigerant charge if the system was charged during heating To compensate for this charge difference some outdoor unit manufacturers have a charge compensator device that stores charge while in heating mode Unfortunately there are no add on devices to accomplish the same thing and only a few usually the most expensive model lines will have one For this reason it is often necessary to compromise the charge Although the unit can be charged in the heating mode it is best to charge the unit during the cooling mode as described earlier Then recheck the charge in the heating mode to be sure the system is not over charged Charging in Heating Mode If the system is started up on heating where the return air temperature is significantly lower than the normal operating range of 65 to 75 F 18 2 to 23 8 C the suction pressure can be very low Operate the system to bring up the return air temperature using auxiliary heat if necessary before checking system charge Copyright 2010 Unico Inc Bulletin 30 10 Page 14 In heating mode the Unico System will have a slightly Table 6a 410A Saturation Table 6b 410A Saturation higher discharge LIQ pressure then a conventional Pressure Temperature Pressure Temperat
38. vertical up flow configuration The vertical rail mounting method is shown in Figure 9 Mark hole pattern on wall and install stud screws or lag screws see Fig 8 Bulletin 30 10 Page 5 To install the unit vertically such as in a closet basement or utility room attach the mounting rails UPC 95 to the top of the unit as explained previously Screw or nail a temporary board to the wall at the bottom of the location where the unit will be mounted The unit will rest on this board during mounting If the wall covering is not adequate enough to hold the weight of the unit use lag screws to attach the rails to the structure Use six 6 lag screws a minimum of 3 inches 77 mm long which will be screwed directly into a stud or structural member If the wall covering is sufficient toggle screws may be used to mount the unit The board can be moved when the mounting of the 1L00171 CV5 Figure 8 Screw Hole Pattern of Mounting unit is completed DUCT CONNECTION Supply Plenum The standard supply plenum is a 7 inch 178 mm diameter duct although this can be reduced to a 6 inch 152 mm Mounting Board temporary 1100162 Cv5 Figure 9 Typical vertical Rail Mounting diameter duct The M1218 plenum adapter UPC 61 1218 provides a convenient connection to a 7 in 178 mm duct The supply plenum can be a 7 inch ID rigid round fiberglass or a sheet metal duct with a minimum thickness of 26 gage Refer to a separa
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