MARCH 1, 2006 REV-1 TABLE OF CONTENTS

Transcription

1 MARCH 1, 2006 REV-1 TABLE OF CONTENTS GENERAL INFORMATION Quick Comparison. 1-2 ENGINEERING SPECIFICATIONS Bulletin M Series Modular Air Cond. & Heat Pump Units. 3-4 Bulletin Accessory Specifications 5-9 Bulletin M1218 Air Handler Bulletin M Series Blower Module 60 hz Specification Bulletin M Series Cooling Module Refrigerant Coil Bulletin M Series Chilled Water Cooling Module Bulletin M Series Heating Module Bulletin Supply Plenum Adapter 38 Bulletin Return Air Plenum Module Bulletin Vertical Plenum Module Bulletin Return Air Adapters Bulletin Sound Attenuator Tubing Bulletin Rigid Sound Attenuator 48 Bulletin Slotted Outlets INSTALLATION & MAINTENANCE INSTRUCTIONS Bulletin Installation Manual M1218 Fan Coil Bulletin Installation M Series Air Handler Units Bulletin Plenum Take-Off Installation Instructions 96 Bulletin Installation Guide Bulletin Outlet Capacities 10% Rule Chart Equivalent Plenum Size 7 & 9 Round 100 Equivalent Plenum Size 10 Round Rule #1.Plenum Length Rule #2.60/40 Rule Rule #3.70/30 Rule Rule #4.Horseshoe Pattern 105 Rule #5.Shotgun Pattern. 106 Rule #6.24 Rule 107 Rule #7.Space Take Offs Even.. 108

2 TABLE OF CONTENTS (CONTINUED) INSTALLATION & MAINTENANCE INSTRUCTIONS (CONTINUED) Rule #1.Plenum Length. 109 Rule #2.The 10% Rule Rule #3.Where can you put an outlet Rule #1.How many outlets in a room Bulletin Air Distribution Manual Bulletin Installation Instructions for Electric Furnaces Bulletin Field Service Report Form Bulletin UniChiller Engineering Specifications Bulletin UniChiller Applications Bulletin Quik-Sizer Instructions TECHNICAL NOTES # 102..Duct Condensation. 155 # 106..Return Duct System # 109..Humidification for Unico # 110..Zoning the Unico System # How to Measure Air Flow # Air Cleaning / Filtering Devices MISCELLANEOUS Condenser Specifications ELECTRICAL Bulletin Installation Advanced Control Box HAFC 201 Wiring Diagram 189 Unico Control Box Systems Overview. 191 PRICE LIST Unico Price List Duct Pictures Capco Prices

3 Mini-Duct Central Heating & Air Conditioning Quick Comparison UNICO VS CONVENTIONAL 250 CFM/nom. Ton 400 CFM/nom. Ton TD TD SHR SHR No drafts Lots of draft Quiet Noisy Small (1/3 area) Big! <8% duct leakage >15% duct leakage 80% duct efficiency 50% duct efficiency

4 Conventional vs. the Unico system

5 Bulletin / June 2005 M SERIES MODULAR AIR CONDITIONING AND HEAT PUMP FAN/COIL UNITS for space-saving installations The innovative Unico System allows central air conditioning and heating installation in applications where the highest comfort is the goal. The Unico System uses a conventional outdoor condensing unit or heat pump in conjunction with a specially designed indoor evaporator fan/coil unit, which distributes air through a high static pressure system of small ducts and plenums. Supply ducts to individual rooms are only 2-inch (50 mm) inside diameter, and can be run over or around structural obstacles or through existing walls and closets where conventional duct will not fit. Plenum duct inside dimensions are 7, 9, or 10-inch. Older buildings, custom homes, commercial offices, and other applications can be air conditioned and heated with a Unico System without major renovations or sacrifice of space. The modular series Unico fan/coil unit is for cooling and/or heating applications, and is available in three sizes which cover cooling capacities from 2 through 5 nominal tons and heating capacities from 20,000 to 120,000 Btuh using the hot water coil. The unit is modular in construction to accommodate the widest range of options and configurations. The modules easily clamp together and are light enough for one person to install. They can be arranged in a horizontal, upflow, or downflow configuration. There are three basic modules: a cooling module (either an evaporator, heat pump coil, or chilled water coil), the heating module (with hot water coil), and the blower module (with control box). The unit may be matched with most conventional condensing units or heat pumps of proper capacity. An optional multi-staged electric duct heater, up to 20 kw, mounts to the discharge of the blower to provide the most compact installation. Cabinet construction is galvanized steel and fully insulated. The Unico System cooling module (MC) uses a deep copper tube/aluminum fin coil that produces superior moisture removal compared to a more conventional system. It comes standard with a corrosion resistant primary drain pan to provide lifetime protection; the condensate drain is ¾-inch FPT. The refrigerant coil module is equipped with a factory installed thermostatic expansion valve and freeze protection controls for proper operation and to prevent icing. Water coils are equipped with a drain and a vent valve. All Unico System blower modules (MB) include a 208/230 volt, single phase direct-drive blower isolated from the conditioned air stream. The control box, which houses the variable speed motor control, blower relay(s), control transformer, and high and low voltage terminal blocks, is shipped with the blower module and can be installed either on the top or side of the unit. The blower module can also be purchased or upgraded with the ACB control for additional functions. Duct, plenums, secondary drain pans, connectors, and fittings are ordered separately according to individual job requirements. Specify round or square plenum connection when ordering. NOTE: The Unico System operates at a higher static pressure than conventional duct systems and has unique design and layout requirements for proper air distribution. It is important that the manufacturer's installation instructions be followed exactly to achieve maximum effectiveness. NOTE Specifications, Ratings, and Dimensions are subject to change without notice. Copyright 2005 Unico, Inc.

6 Bulletin Page 2 Install Kit Elbow Full Flow Tee with turning vane End Cap Blower Module Cooling Module Heating Module Plenum Adapter Plenum Secondary Drain Pan Return Air Adapter Return Air Duct Return Air Box il00323.cnv BLOWER MODULE - 208/230 VOLT, 60 HZ, 1 PH (Includes control box) MOTOR CFM DIMENSIONS SHIP MFR. NO. HP 1.5 E.S.P. H W D WT. MB2430L ½ MB3642L MB4860L HEATING MODULE (Without heating coil) DIMENSIONS SHIP MATCHING HOT WATER COIL ELECTRIC HEAT MFR. NO. H W D WT. MFR. NO. MAX. CAPACITY, BTUH OPTIONS, kw MH HW ,800 5, 7.5, 10, 15 MH HW ,000 5, 7.5, 10, 15, 20 The MH3660 matches both the 3642 and 4860 blower and cooling modules REFRIGERANT COOLING MODULE (Includes R-22 refrigerant coil and expansion valve) COOLING ONLY HEAT PUMP NOMINAL CONNECTIONS DIMENSIONS SHIP MFR. NO. MFR. NO. TONS INLET OUTLET H W D WT. MC2430C MC2430H 2 THRU 2½ 3/8 OD 7/8 OD MC3642C MC3642H 3 THRU 3½ 3/8 OD 7/8 OD MC4860C MC4860H 4 THRU 5 3/8 OD 7/8 OD CHILLED WATER COOLING MODULE (Includes water coil*) MAX. COOLING DIMENSIONS SHIP MFR. NO. CAPACITY, BTUH CONNECTIONS H W D WT. MC2430W 38,100 7/8 OD MC3660W 63,000 7/8 OD * can also be used with hot water for 2-pipe systems

7 The Unico System Return Grille & Filter Bulletin / May 2005 Accessory Specifications Air Filter Includes throwaway filter, two duct bands, and clips. Rough-in dimensions are shown. B A 1 Ea./Box 1.0 (25) Pleated 1.0 (25) Throwaway P/N SIZE TYPE P/N Duct Dimensions Filter A x 25 (350 x 625) Pleated Dia. A B size A x 30 (350 x 750) Pleated UPC UPC UPC UPC (300) 14 (350) 18 (450) 20 (508) (514) (631) (756) (756) (362) (362) (362) (594) 14 x 20 (350 x 500) 14 x 25 (350 x 625) 14 x 30 (350 x 750) 24 x 30 (610 x 750) A x 20 (457 x 500) Pleated A x 25 (457 x 625) Pleated A x 18 (457 x 457) Pleated A x 30 (610 x 750) Pleated A x 25 (350 x 625) Throwaway A x 30 (350 x 750) Throwaway A x 20 (350 x 500) Throwaway A x 38 (350 x 965) Throwaway A x 30 (610 x 750) Throwaway Adapter, Return Air, Cooling Module C A Return Air Duct Includes insulation wrap shipped loose. P/N Used On Duct Dia. B 1 Ea./Box Overall Dimensions A B C 1 Ea./Box Tough Aluminized outer mylar wrap Spun-bonded nylon and helical wire core 1" (25 mm) Fiberglass insulation, R ft (3050 mm) lengths UPC (350) 23 (575) 13.5 (338) 11.5 (288) P/N Used On Dia. UPC UPC (450) 20 (508) 35 (875) 35 (875) 13.5 (338) 11.5 (292) 10.5 (263) 15.0 (381) UPC UPC UPC UPC (300) 14.0 (350) 18.0 (450) 20.0 (508) Adapter, Return Air, Heating Module Adapter, Return Air, M each/box Mates directly to Heating Module or Vertical Plenum Module No additional fabrication Can be used on either horizontal or vertical installations Mates directly to air handler No additional fabrication Can be used on either horizontal or vertical installations 1 each/box All dimensions are in inches (mm) unless otherwise noted. Copyright 2005 Unico, Inc. NOTE Specifications, Ratings, and Dimensions are subject to change without notice.

8 Bulletin Page 2 Outlet Kits (1 Outlet) Installation Kits (6 or 8 Outlets) UPC-80F only UPC-80M only Outlet Kits, Short (5 Outlets) UPC-84-5 only UPC-85-5 only UPC-89F only UPC-89M only Secondary Drain Pan Mounting Rails, M1218

9 Bulletin Page 3 15 or 25 UPC-56B UPC-57 UPC-58-1-XX XX = angle of ceiling IL00113.CV5 Copyright 2005 Unico, Inc.

10 Bulletin Page 4 Supply Air Plenum Adapter, Round P/N Used On Overall Dimensions A B L Dia. D 1.0 (25mm) insulation blanket provided UPC (same as UPC-93) UPC UPC (203) 7.5 (191) 8.68 (220) 4.75 (121) 8.0 (203) 8.0 (203) 12.0 (305) 12.0 (305) 18.0 (457) 7.0 (178) 7.0 (178) 9.0 (229) 1 Ea.\ Box UPC (295) 8.0 (203) 18.0 (457) 10.0 (254)

11 Bulletin Page 5 P/N Used On Dimensions A Duct size** Includes: restrictor plate insulation tape mounting screws UPC (same as UPC-62) UPC UPC (216) 8.5 (216) 10.5 (267) 6.5 x 6.5 (165 x 165) 6.5 x 6.5 (165 x 165) 8.5 x 8.5 (178 x 178) UPC (292) ** Based on inside dimension of 1-inch (25 mm) fiberglass ductboard 9.5 x 9.5 (241 x 241) Copyright 2005 Unico, Inc.

12 Bulletin / August 2005 M1218 Air Handler Applications 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. 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 verticalupflow or horizontal-flow configuration. The coils can be combined as a heating-only, cooling-only, or heating and cooling fan coil unit. For cooling, the M1218 offers a choice between R-22 or R-410A refrigerant (both A/C and Heat Pump) or a chilled water coil. For heating, the M1218 offers an optional hot water, or you may use the installed heat pump coil or chilled water coil (using hot water). The M1218 is designed to deliver up to 350 CFM (0.17 m 3 /s) of air with a static pressure of 1.5 inches of water (373 Pa). The minimum airflow for refrigerant systems is 200 CFM per nominal ton (27 L/s per nominal kw) Cabinet Construction The cabinet is fully insulated with closed cell insulation. There is no exposed fiberglass inside the cabinet. The cabinet is constructed of 22 gauge (0.7-mm) galvanized steel with removable access panels on both sides for ease of service. See Dimension drawing. FEATURES AND CONTROLS Unico designed and built blowers feature direct drive motors that are located in the air stream. Each blower wheel is balanced to Unico specifications. The blowers are capable of generating external pressures up to 1.5 inches of water (373 Pa). See the Electrical Characteristics section of the Blower Specification Table on the last sheet of this manual for motor specifications. A control box is provided with the blower module. It is located inside the air handler. Other controls include a 24 volt transformer and the necessary blower relays. All connections are made to terminal blocks. The most convenient and simplest way to achieve constant ventilation with the Unico System is to use the ACB (Advanced Control Board). The ACB can be used with both standard three-speed and the two-speed MP motors and is suitable for use with just about every configuration. Refer to Bulletin for more information on this advanced feature. C INTERTEK LISTED CM US CERTIFIED TO UL STD 1995 CONFORMS TO CAN/CSA STD C22.2 NO. 236 Typical M1218 Horizontal Installation IL00322.cvs Copyright 2005 Unico, Inc.

13 Bulletin Page 2 20 (508) 38 ( 965) 3 (76) 6 ( 152) 12 (305) IN OUT 10 (254) 15 ( 381) All dimensions in inches (mm) Blower Capacity Data 1 ph / 230V / 60 Hz Motor Speed Standard Static Pressure, inches of water (Pa) 1.0 (248) 1.25 (310) 1.5 (372) 1.75 (435) 2.0 (496) CFM (m 3 /s ) Amps CFM (m 3 /s ) Amps CFM (m 3 /s ) Amps CFM (m 3 /s ) Amps CFM (m 3 /s ) Amps High 450 (0.21) (0.20) (0.18) (0.16) (0.14) 1.44 Medium 400 (0.19) (0.18) (0.16) (0.14) (0.11) 1.05 Low 350 (0.17) (0.15) (0.14) (0.12) 1.06 Two-Speed High 465 (0.22) (0.21) (0.19) (0.17) (0.13) 1.19 Low Low-speed airflow is half of rated high speed airflow at 1.0 amp with static pressure less than 0.5 inches of water (125 Pa) Entering Water Temperature F C 120 (48.9) 130 (54.4) 140 (60) 150 (65.5) Hot Water Coil Performance Airflow, SCFM (m 3 /s) Water Flow rate 200 (0.09) 300 (0.14) 400 (0.19) Capacity Capacity Capacity WPD GPM (L/s) MBH (KW) MBH (KW) MBH (KW) ft. water (KPa) 2 (0.13) 10.2 (2.97) 13.7 (4.01) 16.2 (4.76) 0.9 (2.69) 4 (0.25) 10.6 (3.10) 14.9 (4.37) 18.5 (5.42) 3.2 (9.57) 6 (0.38) 10.7 (3.13) 15.3 (4.49) 19.3 (5.65) 7.1 (21.23) 2 (0.13) 4 (0.25) 12.2 (3.58) 12.7 (3.72) 16.5 (4.83) 18.0 (5.26) 19.6 (5.75) 22.3 (6.52) 0.9 (2.69) 3.2 (9.57) 6 (0.38) 12.8 (3.76) 18.4 (5.40) 23.2 (6.79) 7.1 (21.23) 2 (0.13) 4 (0.25) 14.3 (4.19) 14.8 (4.35) 19.3 (5.66) 21.0 (6.15) 23.0 (6.74) 26.1 (7.64) 0.9 (2.69) 3.2 (9.57) 6 (0.38) 15.0 (4.39) 21.5 (6.31) 27.1 (7.94) 7.1 (21.23) 2 (0.13) 4 (0.25) 16.4 (4.79) 17.0 (4.98) 22.2 (6.50) 24.1 (7.05) 26.4 (7.75) 29.9 (8.75) 0.9 (2.69) 3.2 (9.57) 6 (0.38) 17.1 (5.02) 24.6 (7.22) 31.0 (9.10) 7.1 (21.23) 2 (0.13) 4 (0.25) 18.4 (5.40) 19.1 (5.60) 25.0 (7.33) 27.1 (7.94) 29.9 (8.76) 33.7 (9.88) 0.9 (2.69) 3.2 (9.57) 160 (71.1) 6 (0.38) 19.3 (5.65) 27.7 (8.13) 35.0 (10.25) 7.1 (21.23) 2 (0.13) n/a n/a 27.9 (8.17) 33.3 (9.77) 0.9 (2.69) 170 (76.7) 4 (0.25) n/a n/a n/a n/a 37.5 (11.00) 3.2 (9.57) 6 (0.38) n/a n/a n/a n/a 38.9 (11.41) 7.1 (21.23) Minimum Number of Outlets Copyright 2005 Unico, Inc.

14 Bulletin Page 3 Entering Water Temperature F C 35 (1.7) Water Flowrate GPM (L/s) 3 (0.19) 4 (0.25) Chilled Water Coil Performance (Cooling Mode) Airflow, SCFM (m 3 /s) 200 (0.09) 300 (0.14) 400 (0.19) Capacity Capacity Capacity MBH (KW) SHR MBH (KW) SHR MBH (KW) SHR 13.6 (3.98) (5.03) (5.77) (4.23) (5.53) (6.48) 0.60 WPD ft. water (KPa) 1.8 (5.37) 3.4 (10.15) 5 (0.32) 14.9 (4.37) (5.86) (6.98) (15.83) 3 (0.19) 11.8 (3.46) (4.38) (5.03) (5.37) 40 (4.4) 4 (0.25) 12.6 (3.69) (4.81) (5.63) (10.15) 5 (0.32) 13.0 (3.81) (5.10) (6.06) (15.83) 3 (0.19) 10.0 (2.92) (3.69) (4.27) (5.37) 45 (7.2) 4 (0.25) 10.6 (3.10) (4.05) (4.75) (10.15) 5 (0.32) 11.0 (3.21) (4.28) (5.10) (15.83) 3 (0.19) 8.0 (2.34) (2.99) (3.49) (5.37) 50 (10.0) 4 (0.25) 8.5 (2.48) (3.25) (3.84) (10.15) 5 (0.32) 8.8 (2.56) (3.42) (4.09) (15.83) 3 (0.19) 6.0 (1.75) (2.30) (2.72) (5.37) 55 (12.8) 4 (0.25) 6.2 (1.83) (2.44) (2.93) (10.15) 5 (0.32) 6.4 (1.88) (2.53) (3.07) (15.83) Minimum Number of Outlets Entering Water Temperature F C 120 (49) 140 (60) 160 (71) Chilled Water Coil Performance (Heating Mode) Water Flowrate GPM (L/s) 3 (0.19) 4 (0.25) 5 (0.32) 3 (0.19) 4 (0.25) Airflow, SCFM (m 3 /s) 200 (0.09) 300 (0.14) 400 (0.19) Capacity Capacity Capacity MBH (KW) MBH (KW) MBH (KW) 8.0 (2.35) 8.1 (2.37) 8.1 (2.38) 12.1 (3.54) 12.1 (3.56) 11.5 (3.37) 11.7 (3.43) 11.8 (3.46) 17.3 (5.07) 17.6 (5.15) 14.5 (4.24) 14.9 (4.36) 15.1 (4.43) 21.8 (6.39) 22.4 (6.56) WPD ft. water (KPa) 1.8 (5.37) 3.4 (10.15) 5.3 (15.83) (5.37) (10.15) 5 (0.32) 12.2 (3.56) 17.7 (5.20) 22.7 (6.66) 5.3 (15.83) 3 (0.19) 4 (0.25) 16.1 (4.72) 16.2 (4.74) 23.1 (6.78) 23.5 (6.88) 29.2 (8.55) 29.9 (8.77) (5.37) (10.15) 5 (0.32) 16.2 (4.76) ) 30.4 (8.90) 5.3 (15.83) 3 (0.19) 4 (0.25) 20.1 (5.90) 20.2 (5.93) 29.0 (8.50) 29.4 (8.62) 36.6 (10.72) 37.5 (10.99) (5.37) (10.15) 180 (82) 5 (0.32) 20.3 (5.95) 29.6 (8.68) 38.0 (11.14) 5.3 (15.83) 3 (0.19) 24.2 (7.09) 34.8 (10.21) 44.0 (12.90) 1.8 (5.37) 200 (93) 4 (0.25) 24.3 (7.12) 35.3 (10.35) 45.1 (13.21) 3.4 (10.15) 5 (0.32) 24.4 (7.14) 35.6 (10.43) 45.7 (13.39) 5.3 (15.83) Minimum Number of Outlets Copyright 2005 Unico, Inc.

15 Bulletin Page 4 Construction Dimensions, inch (mm): Cabinet Type: Insulation: Drain pan: Drain pan connection: Standard Return Duct ID, in (mm): Standard Plenum ID, in (mm): Electrical Type: Power Input, W: Fan Relay: Transformer: Motor Size, hp (kw): Running rated airflow: FLA: RLA: Bearing Type: Blower Wheel Airflow, CFM (m 3 /s): Static Pressure**, in. wc (Pa) Type: Nom. Diameter, inch (cm): Width, inch (cm): Engineering Specifications 12 H x 20 W x 38 L (305H x 508W x 965L) Galvanized 1 inch (25 mm) closed cell vinyl nitrile Stainless Steel 1/2 inch FPT 12 (305) 7.0 (178) 1 ph - 60/50 Hz - 230/208V 310 Snap acting with inherent time-delay 50 VA, 230/208V-24V 1/3 (0.25) 1700/1550/ Refer to Amperage Chart Permanently Lubricated Ball See table See table SISW Forward Curved 9.5 (24) 1.5 (3.8) Unico Part No. A00056-G02 A00057-G02 A Standard A Two-speed A Refrigerant Coil (AC or HP option) Nominal Capacity, tons (kw): Rated Airflow, CFM (m 3 /s): Min. Airflow, CFM/ton (m 3 /s kw): Refrigerant Type: Face Area, ft² (m²): Number of Rows: Number of Circuits: Fin Density, fins/in. (fins/cm): Fin Type and pattern, in. (mm): Tube Diameter, in (mm): Tube Type: Expansion Device (AC option) Expansion Device (HP option): Liquid Line Connection OD, in. (mm): Suction Connection OD, in. (mm) : Hot Water Coil (HW option) Fluid Type Face Area, ft² (m²) Number of Rows Number of Circuits Fin Density, fins/in. (fins/cm): Fin Type and pattern, in. (mm): Tube Diameter, in (mm): Connection OD SWT, in (mm): 1 to 1.5 (3.5 to 5) 400 (0.189) 200 (0.027) R-22, R407C, R410A (0.108) (6) Corrugated, 1 x (25.40 x 15.88) 3/8 (9.53) Rifled TXV with Bleed Port TXV with Bleed Port and Check Valve 3/8 (9.53) 5/8 (15.88) Water or Glycol-Water Solution 1.0 (0.093) (4) Raised Lance, 1 x.866 (25.40 x 22.00) 3/8 (9.53) 5/8 (15.87) A A (R-22) A (R410A) A (R-22) A (R410A) HW-1218 ** Static pressure across unit without hot water coil, using 6 inch ID plenum. Motor speed factory default is medium. Static pressure will be greater when using 7 inch ID plenum. Copyright 2005 Unico, Inc.

16 Bulletin Page 5 Wheel: FC D Housing: 950M Motor: 1/3 HP, 1700 RPM (Dayton Model 9DM89) Equip: M1218+AC Supply: Metal duct, 7" dia., 5 feet to tee, then horseshoe configuration M Hz Wheel: FC D Housing: 950M Motor: 1/3 HP, 1700 RPM (Dayton Model 9DM89) Equip: M1218+AC Supply: Metal duct, 7" dia., 5 feet to tee, then horseshoe configuration Return: UPC (12" flex) connected to UPC (14 x 20" filter) with two 90 bends M Hz Return: UPC (12" flex) connected to UPC (14 x 20" filter) with two 90 bends Temperature: 66.2 F dry bulb Temperature: 66.2 F dry bulb L/s L/s High Speed Medium Speed RPM RPM V 208V 250V 230V V 300 RPM Static Pressure, in. wc Amps Watts Static Pressure, in. wc Amps Watts V 230V 250V 230V 208V 250V 600 Pa Pa RPM Static Pressure, in. wc Watts Amps Watts Static Pressure, in. wc Amps Airflow, CFM V Airflow, CFM R0301 _ Catalog R0301 _ Catalog Graph1 Graph3 1/15/2003 1/15/2003 Tested by: J. Riley Tested by: J. Riley Approved by: C. Messmer Approved by: C. Messmer Wheel: Revcor BC S Wheel: FC D Housing: 950M M1218 Housing: Revcor 950M M1218+CB Motor: 1/3 HP, 1625 RPM, Dayton A19844 Motor: 1/3 HP, 1700 RPM (Dayton Model 9DM89) Equip: M AC Equip: M1218+AC 60Hz Supply: 7" sheet metal duct to 9" sheet metal, straight to 1 tee, horse shoe 60 Hz Supply: Metal duct, 7" dia., 5 feet to tee, then horseshoe configuration Low Speed Return: UPC (12" flex) connected to UPC (14 x 20" filter) with two 90 bends Return: 12" with filter across the duct opening (no grille) V Temperature: 68.9 F, 32.4% RH Temperature: 66.2 F dry bulb L/s L/s V 230V 208V 230V 250V V High Speed Low Speed 208V High Speed Low Speed High Speed Low Speed V 230V 230V 250V 250V Pa Pa 208V 230V 250V Airflow, CFM R0301 _ Catalog Graph2 1/15/2003 Tested by: J. Riley Approved by: C. Messmer Airflow, CFM 0337 Graph7 01/15/2004 Tested by: J. Riley Approved by: C. Messmer Copyright 2005 Unico, Inc.

17 Bulletin / December 2002 M SERIES BLOWER MODULE 60 Hz Applications The Unico designed and built blower module can be easily installed with the matching Unico System heating or cooling module. It is designed to match the airflow requirements of the Unico System small-duct highvelocity system. The blower module is designed for multi-position installation in a basement, attic, crawlspace, or closet. The blower module comes in several styles differentiated by the last few letters in the model number. All are single speed motors; the difference is primarily the speed of the motor and the application. L models (standard model) are the most economical to operate and readily available. They are designed for all 60 Hz applications requiring 1.5 inches of water (373 Pa) static pressure H models are replacement units for systems built prior to 1993, with very restrictive duct systems matched to condensers less than 5 ton. In most cases, it is more economical to bring the duct system into compliance with current design practice and use the standard model. The Unico System is designed for a minimum of 200 CFM per nominal ton (27 L/s per nominal kw) although the blowers are capable of 250 CFM per nominal ton (34 L/s per kw). Refer to Blower Performance Curves, for proper selection based on static pressure and air flow requirement. Typical Application Typical MB2430L with cutaway revealing motor Table 1. Standard Modules Blower Module Heating Module Matching Unit Cabinet Construction Cooling Module MB2430L MH2430 MC2430(C,H,W) MB3642L MC3642(C,H,W) MH3660 MB4860L MC4860 (C,H,W) Note: Model numbers listed above do not include the latest revision code. Table 2. Replacement Modules Blower Module Heating Module Matching Unit Cooling Module MB2436H MH2430 MC2430(C,H,W) MB4260H MH3660 MC3642(C,H,W) Note: Model numbers listed above do not include the latest revision code. The cabinet is fully insulated with closed cell insulation. There is no exposed fiberglass inside the cabinet. The cabinet is constructed of 22 gauge (0.7-mm) galvanized steel with removable access panels on both sides for ease of service. See Dimension drawing. IL00022c.cvs Attic Installation with Unico System Cooling Module, Heating Module, and Blower Module C L I S T E D CERTIFIED TO UL STD 1995 CONFORMS TO CAN/CSA STD C22.2 NO. 236 Unico products comply with the European regulations that guarantee the safety of the product. Copyright 2002 Unico, Inc.

18 Bulletin Page 2 FEATURES AND CONTROLS Unico designed and built blowers feature direct drive motors that are located in the air stream. Each blower wheel is balanced to Unico specifications. The blowers are capable of generating external pressures up to 1.5 inches of water (373 Pa). A movable restrictor plate is mounted to the exterior of the unit for proper airflow adjustment. See the Electrical Characteristics section of the Blower Specification Table on the last sheet of this manual for motor specifications. These blowers have two new features. They feature a quick twist-and-lock motor mount for easy maintenance. They also feature a ventilation speed that is adjustable down to half airflow. 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. When service is required to the motor or the wheel, the entire assembly may be removed as a whole. See Figure 1. A separate control box is provided with the blower module. It mounts to the top or front of the cabinet. Knockout and starter holes for the screws are provided to assist in mounting. All units include a variable speed motor controller to adjust the proper airflow for constant ventilation where required by code or desired by the resident. Figure 1. Removal of the Motorized Blower Assembly Other controls include a 24-volt transformer and the necessary blower relay. All connections are made to terminal blocks. Space is provided for a heat pump heating mode bypass relay (shipped with cooling module). Space is also provided for an additional double pole double throw (DPDT) relay for wiring a boiler. Blower module controls and components are bonded for grounding to meet safety standards UL 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. Blower Performance Static Pressure, iwc. (Pa) 1.0 (248) 1.25 (310) 1.5 (372) 1.75 (435) 2.0 (496) Model CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps 60 Hz 230V MB2430L 867 (409) (383) (351) (310) (240) 2.0 MB3642L 1240 (585) (552) (505) (437) (352) 3.1 MB4860L 1472 (695) (660) (613) (548) (450) 3.4 Copyright 2002 Unico, Inc.

19 Bulletin Page 3 Blower Module Specifications 60 Hz Model No. MB2430L MB3642L MB4860L Motor Electrical Characteristics Volts / 60 / 1 phase Size, HP (kw) 1/2 (0.37) 1 (0.75) 1 (0.75) Full Load Amps Capacitor, mfd Speed, RPM Blower Wheel Nom. Diameter, in. (mm) 9.5 (241) 9.5 (241) 9.5 (241) Blower Wheel Width, inch (mm) 3.75 (95) 5.0 (127) 7.75 (197) Nominal* Air Flow Rate, cfm (L/s) 600 (283) 1000 (472) 1250 (590) Plenum Static Pressure, iwc, (Pa) 1.5 (373) 1.5 (373) 1.5 (373) Sound Pressure Level db(a) NC Minimum Plenum Size, ID, inch (mm) 7 (178) 9 (229) 10 (254) Shipping Weight, lb (kg) 62 (28) 72 (33) 72 (33) Dimensions, in. (mm) * based on full open restrictor and minimum plenum size at 230V. ** NC=noise criteria A 25 (635) 38 (965) 38 (965) B 6.00 (152) 7.16 (182) (257) C 6.38 (162) 6.38 (162) 6.38 (162) D 23 (584) 36 (914) 36 (914) A LATCH CATCH TOP VIEW CONTROL BOX 9.55 (243) 4.29 (109) 7.55 (192) RESTRICTOR PLATE OUTLET OPENING (FULL) C 10 (254) KNOCKOUTS (ALTERNATE CONTROL BOX LOCATION) INLET OPENING 17-1/2 (445) 15-1/2 (394) x 'D' Width AIR FLOW B 13-3/4 (349) 1 (25) FRONT VIEW PLENUM ADAPTER SOLD SEPARATELY SIDE VIEW IL00020B.CNV ALL DIMENSIONS IN INCHES (mm) Copyright 2002 Unico, Inc.

20 Bulletin Page 4 Acoustical Data Sound is always present in our lives and is important to comfort. Understanding how sound is defined is essential to understanding how to design a proper Unico System. Sound is defined as a physical disturbance in pressure that is detectable by the human ear. Sound is usually presented as Sound Pressure Level (SPL) in decibels (db), but can also be presented as Sound Power Level (SWL). Sound pressure is what you hear so it is the only value that is important to the occupant. However, determining the value is difficult because it is dependent on the surroundings and distance from the sound source. For instance, a carpeted room is much quieter than a room with wood floors. For the Unico System, it is also important to consider sound transmission losses through ceilings and walls. The blower is never placed in the occupied room so the sound is always less than the published value. This reduction in sound level depends on the construction of the ceiling or wall. For instance, a ceiling structure made of gypsum board with insulation above it will have a much greater sound transmission loss (TL) than a dropped ceiling without insulation. The data shown in this catalog was measured in a large room with hard surfaces for the walls and floor. It is considered to the worst case (i.e. loudest) situation. The sound level in the occupied space will always be considerably less than this, depending on where the unit is located. To determine the actual sound level, subtract the TL for the barrier from the sound data of the unit. The table below shows typical TL values for common construction configurations. Subtract these values from the Unico air handler data. Transmission Loss for Common Construction, db Frequency, Hz k 2k 4k R Sheet Metal, 24 ga Ceiling Tile, mineral fiber Gypsum Frame wall Gypsum Frame wall, insul Wood Floor, uninsulated Wood Floor, insulated Concrete Block, 190-mm Concrete, 100-mm (4 in.) Ref: Handbook of Acoustical Measurements and Noise Control, 1998 R = Overall Loss for typical Blower Module (based on MB4260H-50HZ) For example, if a MB2430L operating at 50 Hz is located above a dropped ceiling, the noise level in the room will be reduced 20 db, from 52 to 32 dba, making the Unico System one of the quietest systems on the market. Similarly, if the same unit is installed in an attic with insulation, the sound level will only be 29 db in the room. Sound Pressure Level, db(a) re 20 µpa Sound Pressure Level, db(a) re 20 µpa Sound Pressure Level, db(a) re 20 µpa V - 50 Hz Hz V - 60 Hz Measured 3 ft. (1 m) from unit (side opposite control box) 21 ft. x 35 ft. lab (school classroom). Tested 9/12/ Hz 250 Measured 3 ft. (1 m) from unit (side opposite control box) 21 ft. x 35 ft. lab (school classroom). Tested 9/12/2002 and 10/2/ Hz - 230V Hz - 220V 500 1k 2k Octave Band Center Frequency, Hz 250 Measured 3 ft. (1 m) from unit (side opposite control box) 21 ft. x 35 ft. lab (school classroom). Tested 10/2/ k 2k Octave Band Center Frequency, Hz k 2k Octave Band Center Frequency, Hz MB2430L 2.0 amps 600 CFM (280 L/s) 4k 4k 4k 8k NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC-25 MB3642L 1000 CFM (470 L/s) 8k 3.9 amps NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC-25 MB4860L 8k NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC M23 NCGraph2-068.M M23 Copyright 2002 Unico, Inc.

21 Bulletin Page 5 Air Wheel: FC D Housing: 950M Motor: 1 HP, 1700 RPM, (Dayton 9MTV8) Equip: MB3642L+MC3642C Supply: 9" sheet metal duct (see photo) Return: UPC-104 connected to UPC-05C terminating into UPC-02E with one 90 bend Temperature: 82 F dry bulb, 55% RH L/s MB3642L 60Hz 1800 RPM V V ft. (1 m) Watts 600 Microphone V 208V Note: Using a muffler made of 10-inch (250 mm) diameter 20-inch (500 mm) long metal duct and lined with 1.5-inch (38 mm) or fiberglass insulation will reduce sound pressure by 3 db. Amps V 208V 700 Blower Capacity Data Static Pressure, in. wc V V 0.5 Supply Static Pressure inch Sheet Metal Duct Airflow, CFM 0241 Graph4 09/18/2002 Tested by: J.Riley Approved by: C. Messmer Pa Wheel: FC D Housing: 950M Motor: 1/2 HP, 1700 RPM, (Dayton 9MTV7) Equip: MB2430L+MC2436C-A Supply: 7" fiberglass duct, straight to 1 tee, horseshoe Return: UPC-104 connected to UPC-05C terminating into UPC-02E with one 90 bend Temperature: 34 F dry bulb, 85% RH L/s MB2430L 60Hz Wheel: FC D Housing: 950M Motor: 1 HP, 1650 RPM, (Dayton Model 9MTV8) Equip: MB4860L+MC4860C Supply: 10" sheet metal duct reduced to 9" to tee (see photo) Return: UPC-104 connected to UPC-05C terminating into UPC-02E with one 90 bend Temperature: 75 F dry bulb, 45% RH L/s MB4860L 60Hz RPM V 230V RPM V 208V Watts V V-230V V Watts V 3 230V V Amps V 1 Amps Static Pressure, in. wc V V inch Rigid Round Supply Duct Airflow, CFM R0201-R0202 Graph1 01/24/2002 Tested by: Seden Kalyoncu Approved by: C. Messmer Pa Static Pressure, in. wc V V inch Sheet Metal Duct Airflow, CFM 0246 Graph3 09/30/2002 Tested by: J.Riley Approved by: C. Messmer Pa Copyright 2002 Unico, Inc.

22 Bulletin / March 2005 M SERIES COOLING MODULE REFRIGERANT COILS for R-22, R-407C, R-410A Package includes: Packing List 1- Cooling Module 2- Latches (MC4860 has 4) 2- Latch Keepers (MC4860 has 4) 8- Screws for latches and keepers (MC4860 has 12) 1- Defrost relay 1-Thermostatic expansion Valve (R-22 or R-410A) 1-Liquid Line, 3/8-inch (9.5-mm) OD 1- Spacer Module (MC4860 only) Features Unobstructed face area for better heat transfer and airflow Easily accessible and replaceable TX Valve Compatible with R-22/407C/410A refrigerants Standard Unico System latch system Applications Unico System designed and built evaporator coil modules can be easily installed with the matching Unico System blower modules. See coil/blower match-up table below. The evaporator can be matched to most types of remote condensing units or heat pumps. See ARI directory or call factory for capacities and ratings. Typical Application Figure 1. Refrigerant Cooling Module with cut-away showing coil Table 1. Matching Blower Modules Cooling Only MC2430C MC3642C MC4860C Evaporator Coil Heat Pump MC2430H MC3642H MC4860H Construction Matching Blower MB2430L MB2430H-50Hz MB3642L MB3660H-50Hz MB4860L MB4860H-50Hz The cabinet is constructed of 22 gauge (0.030-in, mm) galvanized steel with removable access panels on both sides for ease of service. The cabinet is fully lined with closed cell insulation. The cabinet does not contain fiberglass insulation. Easy snap latches are included for quick field assembly. Unico designed coils are constructed of evenly spaced aluminum fins mechanically bonded to copper tubes. The tubes are 3/8" (9 mm) diameter. Full fin collars provide the greatest tube-fin contact for excellent heat transfer. All coils are slanted, except the MC4860C or H model, which feature an A coil to provide the maximum amount of heat transfer surface. Certified to UL Standard 1995 Conforms to CAN/CSA Standard C22.2 NO. 236 C INTERTEK LISTED CM US IL00019f.cvs Horizontal installation with Unico System Heating Module and Blower Module Unico products comply with the European regulations that guarantee the safety of the product. Copyright 2005 Unico, Inc.

23 Bulletin Page 2 The coil is pressure tested and then factory leak tested. The drain pan is constructed of stainless steel for maximum corrosion protection with a 3/4" (19 mm) FPT drain connection. All refrigerant lines are sweat connections extending on the outside of the cabinet. Controls All evaporators are supplied with an expansion valve and anti-frost switch. The heat pump coil includes a TXV with internal check valve for proper operation in the heating cycle. All expansion valves feature mechanical threads (Chatleff type) connections for easy installation. All cooling-only valves include an inlet strainer. Also, for heat pump applications, a 24-volt relay switch that bypasses the anti-frost switch during the heating mode. The switch is packed loose inside the module for field installation in the space provided in the control box. Install the valve as shown in Figure 2. Use the following steps when installing: Expansion Valve Distributor External Equalizer Line Liquid Line Bulb Seal Plate IL00390.CVX (a) 2430/3642 Expansion Valve Installation 1. Remove plastic caps to external equalizer line and distributor inlet. 2. Connect valve to distributor and tighten nut, use new Teflon seal. 3. Connect external equalizer line and tighten flare nut. 4. Connect liquid line to the inlet of the valve using new Teflon seal. Make sure the nut is tight. See Table 2 for liquid line part numbers. Liquid Line Bulb Expansion Valve Distributor External Equalizer Line Seal Plate 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 3 O clock position on a horizontal straight section of the 7/8 (22 mm) suction line (see Figure 2). 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. Insulate the bulb with cork tape to ensure proper valve operation (2430/3642). Always use new Teflon seals when installing or replacing the TXV (Unico Part No. A ). Table 2. Liquid Line Part Numbers. Coil Type AC HP Unico Coil Model No. Liquid Line Part No. MC4860C A MC3642C A MC2430C A MC4860H A MC3642H A MC2430H A (b) 4860 Expansion Valve Installation Figure 2. Expansion Valve Installation Examples IL00392.CVX Example 1. Find the total sensible heat capacity of a 2.5 Ton (8.8 kw) condenser matched to a 2430 system with indoor temperature of 80ºF (27ºC) dry bulb / 66ºF (19ºC) wet bulb. Solution: From graph on page 5 First, determine the total heat capacity, which is defined as the sum of the sensible heat and latent heat. Sensible heat is the energy due to temperature change, whereas latent heat is the energy caused by phase change. In other words, latent heat is associated with the amount of moisture removed from the air and sensible heat is associated with the air temperature drop.

24 Bulletin Page 3 To find the total heat, trace a vertical line from the 66ºF (19ºC) position until it crosses the 2.5 ton (8.8 kw) line. At this point where a horizontal line intersects the vertical line is your Total Capacity in BTU/hr, which is 27,000 BTU/hr. Total Heat = 27,000 BTU/hr (7.9 kw) Next, determine the sensible heat capacity using the Sensible Ratio (SHR) and the total heat capacity from above. The Sensible Heat Ratio (SHR) is defined as the ratio of the Sensible Heat Capacity to the amount of Total Heat Capacity, where: SHR = Sensible Heat Capacity Total Heat Capacity where, TotalHeat = Sensible Heat + Latent Heat To determine the sensible heat ratio, find where the wet bulb temperature crosses the selected condensing unit line. There are a series of solid lined curves numbered 1.0 to The Sensible Heat Ratio is 0.61 Sensible Heat Ratio = 0.61 To determine the sensible heat capacity, take the Total Heat, 27,000 BTU/hr, and multiply it by the Sensible Heat Ratio, Sensible Heat Capacity = 16,470 BTU/hr (4.8 kw) Subtracting this from the Total Heat Capacity gives the amount of Latent Heat. Latent Heat Capacity = 10,530 BTU/hr (3.1 kw) Example 2. Find the outlet temperature of a Unico System Heat Pump at 30ºF (-1ºC) at 200 CFM (27 L/s) per nominal ton (kw). Solution: From the graph on page 8. At the point where 30ºF (-1ºC) crosses the 200 CFM (27 L/s) per nominal ton (kw) line, trace a line until it crosses the Outlet Air Temperature on the vertical axis. Outlet Air Temperature = 107ºF (42ºC)

25 Bulletin Page 4 MC2430x and MC3642x Specifications Type of System Cooling Only Heat Pump Model No. MC2430C-A MC3642C-A MC2430H MC3642H Compatible Condenser Size, Ton (kw) (7 8.8) ( ) (7 8.8) ( ) Net Face Area, ft 2 (m 2 ) 2.13 (0.20) 3.48 (0.32) 2.13 (0.20) 3.48 (0.32) Tube diameter, in. (mm) 3/8 (9.5) Number of rows 4 6 Fins per inch (m) 14 (551) 15.5 (610) Evaporator Suction line O.D., in. (mm) 7/8 (22.2) Coil Fin Type lanced corrugated Number of Circuits Valve, R-22/R-407C, Part No. A A A A Valve, R-410A, Part No. A A A A Liquid line, in. (mm) OD 3/8 (9.5) Condensate Connection, in. (mm) FPT 3/4 (19) Refrigerant R-22, R-407C, R-410A Coil Shipping Weight, lb. (kg) 60 (28) 78 (35) 60 (28) 78 (35) Expansion Device* TXV TXV with internal Check Valve A 25 (635) 38 (965) 25 (635) 38 (965) Dimensions B 23 (584) 36 (914) 23 (584) 36 (914) C 20 (508) 33 (838) 20 (508) 33 (838) * TXV shipped loose

26 Bulletin Page 5 MC4860x Specifications Type of System Cooling Only Heat Pump Model No. MC4860C MC4860H Compatible Condenser Size, Ton (kw) 4-5 ( ) Net Face Area, ft 2 (m 2 ) 7.44 (0.69) Tube diameter, in. (mm) 3/8 (9.5) Number of rows 3 4 Fins per inch (m) 14 (551) Evaporator Suction line, in. (mm) OD 7/8 (22.2) Coil Liquid line, in. (mm) OD 3/8 (9.5) Fin Type sinewave sinewave Number of Circuits 10 8 Valve, R-22, Part No. A A Valve, R-410A, Part No. A A Condensate Connection, in. (mm) FPT 3/4 (19) Refrigerant R-22, R-407C, R-410A* Coil Shipping Weight, lb. (kg) 88 (40) Factory Installed Expansion Device TXV TXV with Check Valve * TXV shipped loose DETAIL OF PIPING 7.94 ( 202) LIQUID LINE CONDENSATE DRAIN TYPICAL FOR TOP DRAIN 4.5 (114) 2.45 (62) SUCTION LINE 6.25 ( 159) 1.75 (45) 1.5 (38) LATCH HOOK TOP VIEW 38 (965) Spacer Module INLE T OPENING 9.6 (245) x (849) AIR FLOW 17.5 (445) 5 (127) 5 (127) OUTLET OPENING 36 (914) IL00283.cnv 6.00 (152) ( 457) SIDE VIEW Spacer Module is shipped with MC4860C/H Cooling Module UNIT SHOWN FOR HORIZONTAL AIRFLOW ARRANGEMENT..ALL DIMENSIONS IN INCHES (mm) FRONT VIEW 3.00 (76)

27 Bulletin Page 6 Cooling Capacity

28 Bulletin Page 7 C MC3642C/H Coil 95 F (35 C) Outdoor 80 F (27 C) Indoor Dry Bulb 1000 CFM (472 L/s) Nominal 10 SEER Condenser Frost Line Ton (17.5kW) 4 Ton (14 kw) 3.5 Ton (12.3 kw) 3 Ton (10 kw) Sensible Heat Ratio (SHR) kw * The 3 ton system is shown with 750 CFM Wet Bulb, F Bulletin fig 4 (revised )

29 Bulletin Page 8

30 Bulletin / August 2005 M SERIES CHILLED WATER COOLING MODULE APPLICATIONS The Unico System designed and built chilled water coil modules can be easily installed with the matching Unico System blower modules (refer to table below). The chilled water coil module can be used for zone cooling in a central chiller system or in combination with a residential chilled water unit. For large applications, multiple systems can be installed to cool more than one zone. Capacities range from 15,400 Btu/hr to 52,400 Btu/hr (4.5 to 15kW) for cooling and 19,200 Btu/hr 127,900 Btu/hr (56 to 37.5 kw) for heating. For smaller applications use the M1218 unit (See Bulletin 30-10). Chilled Water Module MC2430W MC3660W Matching Blower MB2430L MB243H-50HZ MB3642L MB4860L MB3660H-50HZ Figure 1. Chilled Water Cooling Module CABINET CONSTRUCTION The cabinet is constructed of 22 gauge (0.030-in, mm) galvanized steel with removable access panels on both sides for ease of service. The cabinet is fully lined with closed cell insulation. The cabinet does not contain fiberglass insulation. Easy snap latches are included for quick field assembly. Refer to dimensional drawing for sizes. COIL CONSTRUCTION Unico System designed coils are constructed of evenly spaced aluminum fins mechanically bonded to copper tubes. The tubes are 3/8-inch (9.5 mm) outside diameter. Full fin collars provide the greatest tube-fin contact for excellent heat transfer. The coil is pressure tested and then factory leak tested. The drain pan is constructed of stainless steel for maximum corrosion protection with a 3/4-in (19-mm) FPT drain connection. All water lines are sweat connections extending outside of the cabinet. IL00019c.cvs Typical Horizontal Installation with Unico System Chilled Water and Blower Module Certified to UL Standard 1995 Conforms to CAN/CSA Standard C22.2 NO. 236 C INTERTEK LISTED Unico products comply with the European regulations that guarantee the safety of the product. CM US Copyright Unico, Inc.

31 Bulletin Page 2 Model No. MC2430W MC3660W Net Face Area sq. ft. (m 2 ) (0.20) (0.32) Water Coil Tube Diameter in. (mm) 3/8 (9.5) 3/8 (9.5) No. of Rows 6 6 Fin Density fins/in. (fins/m) 15.5 (610) 15.5 (610) Water Connection Size, ODF Sweat in. (mm) 7/8 (22.2) 7/8 (22.2) Condensate drain connection size, FPT in. (mm) 3/4 (19) 3/4 (19) A 25 (635) 38 (965) Dimensions in. (mm) B 23 (584) 36 (914) LATCH KEEPER C 20 (508) 33 (838) Shipping Weight, lb (kg) 60 (27) 78 (35) Coil Water Volume, gal. (liters) 0.8 (3.6) 1.3 (5.9) DETAIL OF PIPING TOP OPENING (ALTERNATE OUTLET) 3-3/4 (95) 2-3/8 (60) CONNECTIONS *SEE NOTE IN OUT CONDENSATE DRAIN 5-3/4 (146) LATCH HOOK TOP VIEW 4-5/8 (117) 1.5 (38) TOP OPENING (ALTERNATE OUTLET) 11-3/4 (298) 1 (25) B AIR FLOW 15.5 (394) OUTLET OPENING 2 (50) Typ. 11-3/4 (298) 17-1/2 (445) 1 (25) Typ. A FRONT VIEW 7 (178) 13-3/4 (349) SIDE VIEW 1 (25) BOTTOM OPENING (ALTERNATE INLET) *NOTE: For counterflow applications reverse water connections. UNIT SHOWN FOR HORIZONTAL AIRFLOW ARRANGEMENT. USE ALTERNATE OPENINGS FOR VERTICAL ARRANGEMENT. ALL DIMENSIONS IN INCHES (mm) Copyright 2005 Unico, Inc.

32 Bulletin Page 3 MC2430W Entering Water Water Flow Rate, Temp., gpm (L/s) F ( C) 40 (4.4) 45 (7.2) 50 (10) Chilled Water Coil Performance (Cooling Mode) Airflow, CFM (L/s) 400 CFM (190 L/s) 500 CFM (240 L/s) 600 CFM (280L/s) 700 CFM (330 L/s) Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw)) SHR Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Water Pressure Drop, ft. water (kpa) 2 (0.13) 17.3 (5.1) (5.6) (6.2) (6.7) (2.1) 4 (0.25) 21.7 (6.4) (7.2) (8.0) (8.5) (10.2) 6 (0.38) 24.0 (7.0) (8.2) (9.2) (10.1) (22.4) 8 (0.50) 25.0 (7.3) (8.7) (9.9) (11.1) (38.3) 2 (0.13) 14.9 (4.4) (4.9) (5.4) (5.8) (2.1) 4 (0.25) 18.6 (5.3) (6.2) (6.9) (7.4) (10.5) 6 (0.38) 20.5 (6.0) (7.0) (7.9) (8.6) (22.1) 8 (0.50) 21.4 (6.3) (7.4) (8.4) (9.4) (37.7) 2 (0.13) 11.9 (3.5) ( (4.6) (4.8) (2.1) 4 (0.25) 15.4 (4.5) (5.2) (5.8) (6.3) (10.2) 6 (0.38) 16.8 (4.9) (5.7) (6.5) (7.2) (21.8) 8 (0.50) 17.4 (5.1) (6.0) (6.9) (7.7) (37.4) Minimum No. of Outlets MC3660W Entering Water Flow Rate, Water Temp., gpm (L/s) F ( C) 40 (4.4) 45 (7.2) 50 (10) Airflow, CFM (L/s) 700 CFM (330 L/s) 800 CFM (380 L/s) 900 CFM (430 L/s) 1000 CFM (470 L/s) Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Water Pressure Drop, ft. water, (kpa) 4 (0.25) 30.6 (9.0) (9.6) (10.1) (10.7) (6.0) 6 (0.38) 36.1 (10.6) (11.4) (12.2) (12.9) (14.3) 8 (0.50) 39.2 (11.4) (12.6) (13.5) (14.4) (24.5) 10 (0.63) 41.1 (12.0) (13.3) (14.4) (15.4) (36.8) 4 (0.25) 27.3 (8.0) (8.4) (8.9) (9.5) (6.0) 6 (0.38) 31.8 (9.3) (9.8) (10.5) (11.1) (14.3) 8 (0.50) 34.4 (10.1) (10.8) (11.6) (12.3) (24.2) 10 (0.63) 36.0 (10.5) (11.3) (12.3) (13.1) (36.4) 4 (0.25) 22.7 (6.7) (7.2) (7.7) (8.2) (6.3) 6 (0.38) 25.7 (7.5) (8.2) (8.8) (9.4) (14.0) 8 (0.50) 27.5 (8.1) (8.9) (9.6) (10.2) (23.9) 10 (0.63) 28.7 (8.4) (9.3) (10.1) (10.8) (35.9) Minimum No. of Outlets Entering Water Flow Rate, Water Temp., gpm (L/s) F ( C) 40 (4.4) 45 (7.2) 50 (10) Airflow, CFM (L/s) 1100 CFM (519 L/s) 1200 CFM (566 L/s) 1250 CFM (590 L/s) 1300 CFM (603 L/s) Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Capacity MBtu/hr (kw) SHR Water Pressure Drop, ft. water (kpa) 4 (0.25) 39.5 (11.6) (12.1) (12.4) (12.7) (6.0) 6 (0.38) 47.4 (13.9) (14.5) (14.8) (15.2) (14.3) 8 (0.50) 53.1 (15.6) (16.3) (16.7) (17.1) (24.5) 10 (0.63) 57.1 (16.7) (17.6) (18.1) (18.5) (36.8) 4 (0.25) 35.0 (10.3) (10.8) (11.1) (11.3) (6.3) 6 (0.38) 41.2 (12.1) (12.7) (13.0) (13.3) (14.3) 8 (0.50) 45.7 (13.4) (14.1) (14.4) (14.7) (24.2) 10 (0.63) 48.9 (14.3) (15.1) (15.5) (15.9) (36.2) 4 (0.25) 30.5 (8.9) (9.4) (9.6) (9.8) (6.2) 6 (0.38) 35.0 (10.3) (10.8) (11.1) (11.4) (14.0) 8 (0.50) 38.0 (11.2) (11.8) (12.1) (12.4) (23.9) 10 (0.63) 40.3 (11.8) (12.5) (12.8) (13.2) (35.9) Minimum No. of Outlets * Entering Air Temperature 80ºF (26.7ºC) dry bulb / 67ºF (19.4ºC) wet bulb Copyright 2005 Unico, Inc.

33 Bulletin Page 4 MC2430W Entering Water Temp., F ( C) 120 (49) 140 (60) 160 (71) 180 (82) Water Flow Rate, gpm (L/s) Chilled Water Coil Performance (Heating Mode) Airflow, CFM (L/s) 400 CFM (190 L/s) 500 CFM (240 L/s) 600 CFM (280L/s) 700 CFM (330 L/s) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Water Pressure Drop, ft. water (kpa) 2 (0.13) 15.8 (4.6) 18.4 (5.4) 20.4 (6.0) 20.2 (5.9) 0.9 (2.7) 4 (0.25) 19.2 (5.6) 23.4 (6.9) 27.3 (8.0) 24.9 (7.3) 3.1 (9.3) 6 (0.38) 19.4 (5.7) 23.9 (7.0) 28.0 (8.2) 26.0 (7.6) 6.6 (19.7) 8 (0.50) 19.5 (5.7) 24.0 (7.0) 28.4 (8.3) 26.6 (7.8) 11.3 (33.8) 2 (0.13) 24.2 (7.1) 28.2 (8.3) 31.4 (9.2) 31.3 (9.2) 0.8 (2.4) 4 (0.25) 26.9 (7.9) 32.9 (9.6) 38.3 (11.2) 37.5 (11.0) 3.0 (9.0) 6 (0.38) 27.2 (8.0) 33.5 (9.8) 39.4 (11.5) 39.2 (11.5) 6.4 (19.1) 8 (0.50) 27.3 (8.0) 33.7 (9.9) 39.5 (11.6) 39.9 (11.7) 11.0 (32.8) 2 (0.13) 32.5 (9.5) 38.1 (11.2) 42.7 (12.5) 42.7 (12.5) 0.8 (2.4) 4 (0.25) 34.6 (10.1) 42.3 (12.4) 49.4 (14.5) 50.2 (14.7) 2.9 (8.7) 6 (0.38) 34.9 (10.2) 43.1 (12.6) 50.7 (14.9) 52.4 (15.4) 6.3 (18.8) 8 (0.50) 35.1 (10.3) 43.3 (12.7) 51.2 (15.0) 53.4 (15.6) 10.8 (32.3) 4 (0.25) 42.4 (12.4) 51.8 (15.2) 60.5 (17.7) 68.4 (20.1) 0.8 (2.4) 6 (0.38) 42.7 (12.5) 52.7 (15.4) 62.0 (18.2) 71.3 (20.9) 2.9 (8.7) 8 (0.50) 42.9 (12.6) 53.0 (15.5) 62.7 (18.4) 72.6 (21.3) 6.1 (18.2) 10 (0.63) 43.7 (12.8) 54.0 (15.8) 63.9 (18.7) 73.3 (21.5) 10.5 (31.4) Minimum No. of Outlets MC3660W Entering Water Temp., F ( C) 120 (49) 140 (60) 160 (71) 180 (82) Airflow, CFM (L/s) Water Pressure Drop, ft. water (kpa) Water Flow Rate, gpm (L/s) 700 CFM (330 L/s) 800 CFM (380 L/s) 900 CFM (430 L/s) 1000 CFM (470 L/s) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) 4 (0.25) 34.0 (9.9) 37.9 (11.1) 41.4 (12.1) 44.6 (13.0) 2.1 (6.0) 6 (0.38) 34.9 (10.2) 39.3 (11.5) 43.4 (12.7) 47.3 (13.9) 4.4 (13.0) 8 (0.50) 35.2 (10.3) 39.8 (11.7) 44.2 (13.0) 48.4 (14.2) 7.5 (22.0) 10 (0.63) 35.4 (10.4) 40.1 (11.8) 44.6 (13.1) 49.0 (14.4) 11.3 (34.0) 4 (0.25) 47.7 (14.0) 53.2 (15.6) 58.2 (17.1) 62.7 (18.4) 2.0 (6.0) 6 (0.38) 48.9 (14.3) 55.1 (16.1) 60.9 (17.8) 66.4 (19.5) 4.3 (13.0) 8 (0.50) 49.3 (14.4) 55.8 (16.4) 62.0 (18.2) 67.9 (19.9) 7.3 (22.0) 10 (0.63) 49.6 (14.5) 56.2 (16.5) 62.5 (18.3) 68.7 (20.1) 11.1 (33.0) 4 (0.25) 61.5 (18.0) 68.6 (20.1) 75.0 (22.0) 49.0 (14.4) 1.9 (6.0) 6 (0.38) 62.9 (18.4) 70.9 (20.8) 78.4 (23.0) 52.7 (15.4) 4.1 (12.0) 8 (0.50) 63.5 (18.6) 71.8 (21.0) 79.8 (23.4) 44.6 (13.0) 7.0 (21.0) 10 (0.63) 63.7 (18.7) 72.3 (21.2) 80.5 (23.6) 47.3 (13.9) 10.7 (32.0) 4 (0.25) 75.3 (22.0) 84.0 (24.6) 91.9 (26.9) 99.1 (29.0) 1.9 (6.0) 6 (0.38) 77.0 (22.6) 86.8 (25.4) 96.0 (28.1) (30.7) 4.0 (12.0) 8 (0.50) 77.6 (22.7) 87.8 (25.7) 97.6 (28.6) (31.4) 6.9 (21.0) 10 (0.63) 77.9 (22.8) 88.4 (25.9) 98.5 (28.9) (31.7) 10.5 (31.0) Minimum No. of Outlets * Entering Air Temperature 70ºF (21ºC) dry bulb WARNING To prevent injury or damage from high temperatures, do not install floor outlets when operating in the shaded area. MC3660W Copyright 2005 Unico, Inc.

34 Bulletin Page 5 Entering Airflow, CFM (L/s) Water Pressure Water Flow Rate, Water Temp., 1100 CFM (520 L/s) 1200 CFM (566L/s) 1250 CFM (590 L/s) 1300 CFM (614 L/s) Drop, gpm (L/s) F ( C) ft. water (kpa) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) Capacity, MBtu/hr (kw) 4 (0.25) 45.0 (13.2) 47.5 (13.9) 48.6 (14.3) 47.5 (14.6) 2.1 (6.0) 120 (49) 140 (60) 160 (71) 180 (82) 6 (0.38) 48.5 (14.2) 51.7 (15.2) 53.2 (15.6) 51.7 (16.0) 4.4 (13.0) 8 (0.50) 50.0 (14.6) 53.6 (15.7) 55.3 (16.2) 53.6 (16.7) 7.5 (22.0) 10 (0.63) 50.8 (14.9) 54.6 (16.0) 56.5 (16.5) 54.6 (17.1) 11.3 (34.0) 4 (0.25) 63.4 (18.6) 66.9 (19.6) 68.5 (20.1) 70.0 (20.5) 2.0 (6.0) 6 (0.38) 68.1 (20.0) 72.6 (21.3) 74.8 (21.9) 76.9 (22.5) 4.3 (13.0) 8 (0.50) 70.1 (20.6) 75.2 (22.0) 77.7 (22.7) 80.0 (23.5) 7.3 (22.0) 10 (0.63) 71.2 (20.9) 76.6 (22.5) 79.2 (23.2) 81.8 (24.0) 11.1 (33.0) 4 (0.25) 81.8 (24.0) 86.3 (25.3) 88.4 (25.9) 90.4 (26.5) 1.9 (6.0) 6 (0.38) 87.8 (25.7) 93.7 (27.5) 96.5 (28.3) 99.2 (29.1) 4.1 (12.0) 8 (0.50) 90.3 (26.5) 96.9 (28.4) (29.3) (30.2) 7.0 (21.0) 10 (0.63) 91.7 (26.9) 98.7 (29.0) (30.0) (30.9) 10.7 (32.0) 4 (0.25) (29.4) (31.0) (31.8) (32.5) 1.9 (6.0) 6 (0.38) (31.5) (33.6) (34.7) (35.6) 4.0 (12.0) 8 (0.50) (32.4) (34.8) (35.9) (37.0) 6.9 (21.0) 10 (0.63) (32.9) (35.4) (36.6) (37.8) 10.5 (31.0) Minimum No. of Outlets * Entering Air Temperature 70ºF (21ºC) dry bulb WARNING To prevent injury or damage from high temperatures, do not install floor outlets when operating in the shaded area. Copyright 2005 Unico, Inc.

35 Bulletin / March 2005 M SERIES HEATING MODULE Packing List Carton contains: 1 Cabinet 1 Hook Flange 2 Latch keepers 2 Latches 1 Hot water heating coil (Optional) Gasket as needed. Applications Unico System designed and built heating units can be easily installed with the matching blower and cooling modules. For matchups see table below. The heating module can be matched to a blower module for a heating only system or it can be matched with both a blower and a cooling module for a system that heats and cools. The slide-in hot water/glycol heating coil is supplied separately. Note: The MH2430 replaces the MH2436 and the MH3660 replaces the MH4260. Add HW to Part Number to include the coil, Example MH2430HW (coil included). Table 1. Compatible Modules Heating Module Matching Unit Blower Module Cooling Module MH2430 MB2430L MB2430H-50HZ MC2430(C,H,W) MB3642L MC3642(C,H,W) MH3660 MB4860L MC4860(C,H) MB3660H-50HZ MC3660W Figure 1. Heating Module (access panel removed) Cabinet Construction The cabinet is constructed of 22 gauge galvanized steel. It has a removable panel to insert a hot water coil. The cabinet is fully lined with closed cell insulation. Easy snap latches are included for quick field assembly with the matching modules. Coil Construction Unico designed and fabricated hot water coils are constructed of evenly spaced corrugated aluminum fins mechanically bonded to copper tubes. The tubes are ½-in. diameter on staggered centers. The fins have full collars to provide greater tube-fin contact for excellent heat transfer. The coil is pressure tested at the factory. Bleed and drain valves are provided on the headers outside the cabinet. The coil is sold separately or with the cabinet Certified to UL Standard 1995 Conforms to CAN/CSA Standard C22.2 NO. 236 C INTERTEK LISTED CM US IL00027b.cvs Typical Horizontal Installation with Unico System Blower Module and Cooling Module NOTE Specifications, Ratings, and Dimensions are subject to change without notice. Unico products comply with the European regulations that guarantee the safety of the product. Copyright 2005 Unico, Inc.

36 Bulletin Page 2 Model No. MH2430 MH3660 Coil Model HW-2430 HW-3660 Net Face Area, sq. ft. (m 2 ) 2.08 (0.20) 3.43 (0.32) Tube Diameter, in. (mm) 1/2 (12.7) 1/2 (12.7) Heating Number of Rows 4 4 Coil Fins per inch (m) 12 (472) 12 (472) Connection Size, in. (mm) sweat 7/8 (22.2) 7/8 (22.2) Coil-only Shipping weight, lb. (kg) 33 (15) 47 (21) Dimensions, in. (mm) A 25 (635) 38 (965) B 23 (584) 36 (914) Shipping weight (without coil), lb. (kg) 20 (9) 28 (13) Coil Water Volume, gal. (liters) 0.4 (1.8) 0.7 (3.2) Module Dimensions A 3-1/4 (83) LATCH HOOK TOP VI EW 1(25) TYP. 4-3/8 (111) HOT WATER COIL (OPTIONAL) VENT 2-1/2 (64) 2-1/4 (57) B OPENING OUT AIR FLOW 12-3/8 ( 314) 17-1/2 (445) 15.5 (394) IN FRONT VIEW DRAIN 2-3/8 (60) 12 (305) SIDE VIEW ALL DIMENSIONS IN INCHES (mm) Copyright 2005 Unico, Inc.

37 Bulletin Page 3 HW CFM (0.28 m 3 /s) 15 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (L/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) 26.7 (7.8) 37.5 (11.0) 48.4 (14.2) 59.4 (17.4) 70.4 (20.6) 6 (0.38) 27.7 (8.1) 38.9 (11.4) 50.1 (14.7) 61.4 (18.0) 72.7 (21.3) 8 (0.50) 28.2 (8.3) 39.5 (11.6) 50.9 (14.9) 62.4 (18.3) 73.8 (21.6) 500 CFM (0.24 m 3 /s) 13 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (L/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) 23.0 (6.7) 32.4 (9.5) 41.8 (12.2) 51.2 (15.0) 60.7 (17.8) 6 (0.38) 23.8 (7.0) 33.4 (9.8) 43.0 (12.6) 52.7 (15.4) 62.3 (18.3) 8 (0.50) 24.1 (7.1) 33.8 (9.9) 43.6 (12.8) 53.4 (15.6) 63.1 (18.5) Hot Water Coil Performance Capacity*, MBH (kw) HW CFM (0.59 m 3 /s) 32 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) CFM (0.52 m 3 /s) 28 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) CFM (0.19 m 3 /s) 10 Outlets minimum 1000 CFM (0.47 m 3 /s) 25 Outlets minimum Water Flow, Entering Water Temperature, F ( C) Water Flow, Entering Water Temperature, F ( C) GPM (L/s) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) 19.3 (5.7) 27.1 (7.9) 34.9 (10.2) 42.8 (12.5) 50.7 (14.8) 4 (0.25) (0.38) 19.7 (5.8) 27.7 (8.1) 35.6 (10.4) 43.6 (12.8) 51.6 (15.1) 6 (0.38) (0.50) 19.9 (5.8) 27.9 (8.2) 36.0 (10.5) 44.0 (12.9) 52.1 (15.3) 8 (0.50) (0.63) WARNING To prevent injury or damage from high temperatures, do not install floor outlets when operating in the shaded area. Discharge temperatures in this range can exceed 160 F (71 C) EQUATIONS The general equation of the sensible heat capacity, q, is: q = ρ Q & c p ( T ) (1) where ρ is density, Q & is the volumetric flow rate, c is the specific heat capacity constant, p and T is temperature difference through the coil. The temperature difference is expressed differently depending on whether the fluid is being heated or cooled. It is expressed in the following way Heated fluid: T = T out - T in (2) Cooled fluid: T = T in - T out (3) 900 CFM (0.42 m 3 /s) 23 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) CFM (0.38 m 3 /s) 20 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) CFM (0.33 m 3 /s) 18 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) CFM (0.28 m 3 /s) 15 Outlets minimum Water Flow, Entering Water Temperature, F ( C) GPM (l/s) 120 (49) 140 (60) 160 (71) 180 (82) 200 (93) 4 (0.25) (0.38) (0.50) (0.63) where T in is the inlet temperature of the fluid, and T out is the outlet temperature of the fluid. The fluid is either air or water. * Capacity is based on 70 F (21 C) return air temperature (T in ) Conversion Factors: MBH = 1000 Btu/hr, 1 kw = 3413 Btu/hr Copyright 2005 Unico, Inc.

38 Bulletin Page 4 Equation 1 can be simplified by using standard density and specific heat. If you are at a high altitude please refer to Tech Note 103, High Altitude Applications, for more detailed information about effects of air density. Otherwise, use the following equations to find the leaving fluid temperature. For air: For water: q = 1.08 (CFM) T Btu/hr ( T is in F) (4) q = 1.21 (L/s) T Watts ( T is in C) (5) q = 500 (GPM) T Btu/hr ( T is in F) (4) q = 4.15 (L/s) T kw ( T is in C) (5) Coil Pressure Drop Air Pressure Drop Air Flow rate, P, in. water (kpa) CFM (m 3 /s) HW2430 HW (0.19) 0.07 (0.017) (0.24) 0.10 (0.025) (0.28) 0.12 (0.030) 0.06 (0.015) 700 (0.33) (0.020) 800 (0.38) (0.022) 900 (0.42) (0.027) 1000 (0.47) (0.032) 1100 (0.52) (0.037) 1250 (0.59) (0.047) Example. Consider a MH2430 with 6 GPM (38 L/s) at 140 F (60 C) and 600 CFM (280 L/s). The capacity from the table is 38.9 MBH (11.6 kw). Therefore, the leaving air temperature (LAT) is as follows: LAT = 70 + = 130 F LAT = 21 + = C Likewise, determine the Leaving Water Temperature (LWT) by using one of the following equations: Water Pressure Drop Water Flow rate, P w, ft. water (kpa) GPM (L/s) HW2430 HW (0.25) 4.3 (12.9) 2.6 (7.8) 6 (0.38) 9.3 (27.8) 5.5 (16.4) 8 (0.50) 16.1 (48.1) 9.6 (28.7) 10 (0.63) (43.6) Entering Water Temperature, ºF (ºC) Water Pressure drop = P w x F1 LWT = 140 = 127 F LWT = 60 = C (49) 140 (60) 160 (71) 180 (82) 200 (93) F Copyright 2005 Unico, Inc.

39 Bulletin Page 5 Piping and Thermosiphoning Effect Thermosiphoning is the natural, convective movement of air or water due to difference in temperature. In a hot water system, if the water heater is installed lower than the coil, the hot water will not stay in the water heater when the pump is turned off. The following piping schematic shows how thermosiphoning can be prevented: To tap water Option 1: Check valve Option 2: Solenoid valve Option 3: Zone valve Option 4: Heat trap OPTIONS Domestic Water Source P Automatic Fill Area (optional) Hot Water Coil Water Heater Drain Pressure regulator. Pressure gage. Automatic fill valve. Backflow preventer. Tee. Isolation valve. Expansion tank. Pump. Two-way valve (to drain). Vent/Purge valve. Drain IL00361.CVX OPTION 1: Install a check valve at the supply of the coil, downstream of the pump. OPTION 2: Install a solenoid valve at the supply of the coil, downstream of the pump. OPTION 3: Install a zone valve at the supply of the coil, downstream of the pump. OPTION 4: Add a heat trap at the supply of the coil, downstream of the pump. If the coil is installed lower than the water heater, there is no need for the options mentioned above. Copyright 2005 Unico, Inc.

40 Bulletin / December 2002 Supply Plenum Adapter General All Unico System supply plenum adapters feature a rectangular to round transition. The UPC-61-X (See table below for Part number match-up.) allows air to transition gradually from the blower outlet to the main plenum. Supply Adapter UPC UPC UPC UPC Matching Blower Module M1218 MB2430x MB3642x MB4860x Supply Adapter Construction The supply adapter is constructed of 28 gauge galvanized steel. The supply adapter is insulated with 1- in (25-mm) thick blanket fiberglass which is shipped loose with the supply adapter. See Dimension drawing. Pre-fabricated holes allow for easy installation on the front of the blower module. Figure 1. UPC Dimension, inch (mm) A B D L Model, UPC (165) 6 (152) 3.25 (83) 6.38 (162) 7 (178) 12 (305) (182) (257) 9 (229) 10 (254) 18 (457) 1(25) crimped L A AIRFLOW D B IL00286.cnv Copyright 2002 Unico, Inc.

41 Bulletin / May 2005 Return Air Plenum (RAP) Module Packing List Package includes: 1- Return Air Plenum Cabinet 1- Hook Flange (to connect to Cooling Module) 4- Screws (for latches and keepers 1- Disposable Filter 2- Latches 2- Latch Keepers 1 length of gasket tape Features Blank sides and top allow for custom, multiplereturn openings Centrally located disposable filter Heavy-duty closed cell insulation (no exposed fiberglass insulation) Filter access from both sides Standard Unico System latch system Applications The Unico System designed and built Return Air Plenum (RAP) is easily installed with the matching Unico System modular air-handling units. The RAP is designed specifically for multiple return duct systems. The plenum comes without any return openings so the installer can cut whatever openings are necessary for any number of return ducts. The top and all three sides of the RAP can be used for return air connections. Plus, it includes a centrally located filter accessible from either side of the cabinet. MR2430 Module shown with filter access cover removed The RAP is also ideal for bringing in outside air and combining it with return air, effectively changing the RAP into a mixing box. (Refer to Tech Note 105, Providing Outside Air, and Tech Note 106, Return Duct System Design Requirements for more information.) Return ducts can be any material so long as the duct is insulated, has acoustical properties, and is the correct size. Cabinet Construction The cabinet is fully insulated with closed cell insulation. There is no exposed fiberglass inside the cabinet. The cabinet is constructed of 24 gauge (0.6-mm) galvanized steel with removable access panels on both sides for ease of service. See Dimension drawing. Filter The RAP includes a disposable 1-inch (25 mm) filter. Table 1 lists the sizes. Replace with similar filter type. Do not use filters with over 0.10-inch static pressure drop, such as electrostatic or pleated type. Horizontal installation with Unico System Blower, Cooling, Heating, and Return Air Plenum Modules. Table 1. Filter Data Model Size MR2430 MR3660 Size, inches mm 14 x 25 (356 x 635) 14 x 38 (356 x 965) Max. Airflow, cfm L/s Max. Velocity, fpm m/s Initial Resistance, in. wg Pa Copyright 2005 Unico, Inc.

42 Bulletin Page 2 Providing Outside Air The Unico System is designed to handle up to 100 percent outside air provided the air is filtered and all water coils are freeze protected if necessary. To accommodate outside air, the amount of required airflow must first be established in accordance with all local codes or ASHRAE Standard 62. Outside air is normally based on occupancy, square footage, and use. Refer to Tech Note 105, Providing Outside Air, for more details. The Return Air Plenum provides a convenient plenum box for connecting and filtering the combined air streams from an outside air duct and the inside air ducts. Make up Air Duct Return Air Duct flexible duct should be the sound attenuating type that does not have a solid plastic inner liner. Multiple returns should be used when conditioning two or more spaces that do not communicate with each other. This is particularly important when heating and cooling separate floors with doors separating them or office spaces with closed doors. For multiple return systems, the duct system must be designed for static pressure drop no greater than 0.05 inches of water. Be sure the number and size of the ducts, as designed for the job, provide sufficient area for the capacity of the system. Table 2 provides the minimum return air opening for the system design airflow. This assumes ducts are no longer than 25 feet in length with generous or large radius turns. Where longer lengths and sharp radius turns are necessary, larger ducts must be used (adapters may be required). Table 2. Total Return Opening IL00256.CNV Return air plenum as mixing box Return Duct System Before proceeding with the installation of the Return Air Plenum, the design and layout of the return duct system should be completed considering the following factors: If using return filter grilles, only use one filter. Use the filter that is most convenient for servicing. For optimum acoustical performance metal ducts should be lined with fiberglass insulation and Unit Model Return Air Plenum Model Minimum Total Return Opening 2430 MR in 2 (0.13 m 2 ) in 2 (0.16 m 2 ) MR in 2 (0.20 m 2 ) Where round return ducts are being used, refer to Table 3 to determine the area of the various diameters of return duct. To facilitate connection of round duct to the Return Air Plenum, consider using pre-fabricated connecting stubs or take-offs A Dimensions ( 344) IL00312.CNV ( 445) 12.5 ( 318) B Dimension, in ( mm) A B Model MR2430 MR ( 625) 38 ( 950) 23 (575) 36 (900) Copyright 2005 Unico, Inc.

43 Bulletin Page 3 that are available from supply houses. These are available for connecting either rigid metal pipe or insulated flexible duct. Flexible duct may be retained at the connection stub using duct retaining straps such as the wire tie type. Be sure all return ducts are properly insulated with the required R- factor for the application. Blower Module Cooling Module Heating Module Return Air Plenum Module AIRFLOW Table 3. Diameter to Area conversion Diameter, Area, Diameter, Area, in in 2 mm m Typical Heating and Cooling System Layout Return Air Blower Cooling Plenum Module Module Module Typical Cooling Only System Layout AIRFLOW Return Air Blower Heating Plenum Module Module Module AIRFLOW Typical Heating Only System Layout Blower Module Return Air Plenum Module AIRFLOW IL00344.CNV Typical Blower Only System Layout Copyright 2005 Unico, Inc.

44 Bulletin / August 2005 Vertical Plenum (MV) Module General All Unico System modular air handlers are shipped from the factory configured for horizontal airflow but may be also configured for vertical up-flow with the addition of a vertical conversion kit. Most applications designed for vertical configuration use a base plenum to elevate the unit for proper condensate drainage. The Unico System MV module eliminates the need for the installer to build a base. Features and Scope The MV module features a built in secondary drain pan with a 3/4" PVC socket connection, pleated filter, and place for an optional hot water coil. The MV module features access panels on both sides so that the heating coil may be inserted from either side. The module may be connected to a heating module return adapter, UPC-104, or operate as a free or wild return. If the air is filtered elsewhere, such as at a filter grille, then the central filter in the MV may be removed. The MV2430 matches the MC2430 cooling module in addition to the older MC2436 series; the MV3642 Airflow Blower Module Vertical Spacer Module* Cooling Module 56 in (142 cm) Figure 1. MV Module shown without hot water coil (hot water coil is sold separately). matches the MC3642 and the older MC4260; and the MV4860 matches the MC4860 cooling module. Cabinet Construction The cabinet is constructed of 22 gauge galvanized steel. It has a removable access panel to insert a hot water coil. The cabinet is fully lined with closed cell insulation. The cabinet does not contain fiberglass insulation. Easy snap latches are included for quick field assembly with the mating modules. Optional Hot Water Coil Refer to Bulletin , M Series Heating Module, for hot water coil specifications and performance. The following table indicates the size of hot water coil to be used. Table 1. Hot water coil Model Hot Water Coil Model Maximum Capacity, Btu/hr (kw) MV2430 HW ,000 (20.5) MV3642 MV4860 HW ,000 (41.0) Airflow Return Air Adapter Il00284c.CNV Vertical Heat Module Typical Vertical Installation with Vertical Heat Module Copyright 2005 Unico, Inc.

45 Bulletin Page 2 Specifications Filter Type: Pleated, 1 inch (25 mm) Initial Filter Resistance: 0.22 inches water at 375 FPM (54 Pa at 1.9 m/s) 0.40 inches water at 500 FPM (100 Pa at 2.5 m/s) Table 2. Filter Size and Maximum Airflow Filter (Qty) and Size Maximum Models Airflow, inches mm CFM (L/s) 2430 (1) 18 x 25 (1) 457 x (282) (1) 20 x 18 (1) 18 x 18 (1) 508 x 457 (1) 457 x (590) Dimensions Model MV2430 MV3642 Dimension, inches (mm) A B C D 25 (625) 38 (950) 23 (584) 36 (900) MV (950) 32.11(892) 6.88 (172) 6.88 (172) 9.35 (238) 17.5 (438) 17.5 (438) 23 (584) E 1.0 (25) 1.0 (25) 4.0 (102) D C B E 3/4 inch (19 mm) PVC socket adapter (19) 4.0 (102) 1.25 (32) A Parts List IL00408.cvx **Spacer Module (464) A 17.5 (445) 6 (152) Filter(s) Vertical Plenum Kit Kit includes Vertical Plenum Module Vertical **Spacer Module Pleated Filter(s) 1 Insulated filler plate 2 Corner Brackets Screws Latches Latch Keepers Insulation Strips Vertical Plenum Module D Filler Plate Corner Bracket Features: Everything needed for converting horizontal to vertical system is included Easy to install **Spacer Module is not required or included with the MV4860 Copyright 2005 Unico, Inc.

46 Bulletin / December 2003 Return Air Adapters M1218 Return Air Adapter Part Number UPC x Ellipse X12 ł UPC Return Air Adapter (for all Model 1218 units) Package includes 1 Return Air Adapter, for 12-inch (305 mm) diameter flexible duct 12 sheet metal screws Bead to keep duct from slipping To install the adapter, use the provided sheet metal screws (or any #10 sheet metal screw) to attach to return inlet of the air handling unit. IL00318.CNV Heating Module Return Air Adapter Part Number UPC /3642/4860 Model Number UPC UPC UPC A 25 (635) 38 (965) 38 (965) Dimensions, inch (mm) B 17.5 (445) 17.5 (445) 17.5 (445) C 14 (356) 18 (457) 20 (508) A 2.0 [5.1] Top Duct Size, C B UPC-104 Heating Module Return Air Adapter (for Model 2430, 3642, 4860 units) Package includes: 1-Return Air Adapter Side Front The Heating Module Return Air Adapter fits easily to the Heating Module or Blower Module (for Blower-only systems). Refer to Figure 1 for typical configurations. IL00288b.cnv Note Specifications, ratings, and dimensions subject to change without notice. Copyright 2003 Unico, Inc.

47 Bulletin Page 2 Blower Module Cooling Module Heating Module UPC-104 Blower Module UPC-104 AIRFLOW AIRFLOW Typical Heating and Cooling System Layout Blower Module Heating Module UPC-104 Typical Blower Only System Layout Vertical Heat Module UPC-104 AIRFLOW AIRFLOW IL00287b.cnv Typical Heating Only System Layout Typical Vertical System Layout Typical Configurations with Heating Module Return Adapter Cooling Module Return Air Adapter Part Number UPC /3642/4860 Package includes: 1-Return Air Adapter 1- Insulation Wrap Typical Horizontal Modular System IL00320.CNV UPC-59 Cooling Module Return Air Adapter (for Model 2430, 3642, 4860 units) The Cooling Module Return Air Adapter fits easily to the Cooling Modules. It is used primarily for coolingonly or heat-pump horizontal configurations. C D Ellipse 2.5 [64] E A B Dimensions, inches (mm) Part no. UPC UPC UPC A-Inside Width 20.0 (508) 33.0 (838) 33.5 (853) B-Overall Width 22.0 (559) 35.0 (889) 35.3 (898) C-Inside Height 11.8 (298) 11.8 (298) 9.8 (248) D-Overall Height 13.5 (343) 13.5 (343) 11.5 (292) E-Depth 11.5 (292) 10.5 (267) 15.0 (381) Ellipse 16 x (406 x 298) x (590 x 298) 14 x (356 x 631) Return Duct Diameter 14.0 (356) 18.0 (457) 20.0 (508) IL00319a.CNV Copyright 2003 Unico, Inc.

48 Bulletin / October 2003 Sound Attenuator Tubing Application The sound attenuator significantly reduces sound from the outlets (Figure 2 next page). Therefore, it is essential for proper noise control to use at least 3 feet (1 m) of the sound attenuator at the end of every two-inch branch run (Method B). Alternately, for convenience or better sound attenuation, the entire branch duct can be made of one or more lengths of sound attenuator (Method A). However, because the aluminum core tubing is stronger than the sound core, for lengths greater than 12-feet (3.7 m) it is best to use almost all UPC-25 aluminum supply tubing with a 3-foot (0.9 m) length of sound attenuator at the end (Method B). Where runs are required to be installed in unconditioned spaces every attempt should be made to limit the length of the duct run to 12-feet or less using the proper R-factor for the application. However, as an air duct, there is no limit to the length used other than its ability to deliver the air. UPC-26 C R4-1 quantity per box Nominal R-factor Revision Code For sizing and to determine run capacity, add up all tubing lengths in the run and use the charts or curves provided in Bulletin 40-40, System Sizing and Layout Procedure. Supply Outlet Part No. General The Unico System sound attenuator tubing is a 2-inch (51 mm) Flexible Air Duct designed to reduce the high velocity air noise to a whisper. It also provides an insulated vapor barrier to prevent condensation from forming on the outside of the duct. For a properly designed Unico System it is essential to use the sound attenuator at the end of every branch duct to prevent unwanted noise. The Sound Attenuator is offered with several different choices of insulation thickness. In most cases, the standard sound attenuator should be used. However, for extremely cold or humid environments or where the local building code requires a specific R-factor and the duct is installed in an unconditioned space, use the R4, R6, or R8 products. The R4, R6, and R8 ducts have thicker and heavier insulation than the standard sound attenuator to reduce thermal losses. CONFORMS TO UL STD 181 CERTIFIED TO CAN/ULC STD S110-M86 Sound Attenuator Supply Tubing (12 ft. Max.) (UPC-26C) Scrim Core Clamp (UPC-53) Method A (for 6 to 12 ft. Supply Outlet 3 ft. min Sound Attenuator Supply Tubing Scrim Core Clamp (UPC-53) Scrim Core Clamp (UPC-53) Takeoff (UPC-23B runs) or UPC-28) Alum. Core Clamp (UPC-52) Aluminum Core Supply Tubing (UPC-25) Supply Tubing Coupling (UPC-38C) Takeoff IL00111a.CVS Method B (for 6 to 50 ft. runs) Figure 1: Assembly of Branch Duct Runs Construction The sound attenuator has a 2-inch (51-mm) inside diameter supplied in 12-foot (3.7- m) lengths and can be cut as needed. As shown in Figure 2, the standard sound attenuator (UPC-26C) is made of three layers. These layers combined have an R factor of 3.2 F-hr-ft2/Btu. The inner layer/core consists of a double layer of spunbonded nylon filter material, which is reinforced with a Note Specifications, Ratings, and Dimensions are subject to change without notice. Copyright 2003, Inc.

49 Bulletin Page 2 Mylar Jacket Specifications 3/4 in. Fiberglass Insulation Certifications: UL Standard 181 Flexible Air Ducts ADC Flexible Duct Performance & Installation Standard Spun-bonded Nylon Core Classification: Air Duct per UL Standard 181 Smoke Developed Rating: less than 50 Flame Spread Index: less than 25 Inside Diameter: 2.0 inches (51 mm) Outside Diameter: UPC-26C: 3.5 inch (89 mm) UPC-26CR4: 4.0 inch (102 mm) UPC-26CR6: 5.0 inch (127 mm) UPC-26CR8: 6.0 inch (152 mm) IL00192.CVN Duct Material: Continuous Filament Spunbond Nylon Filter Cloth with helical spring reinforcement Wire Filter Particle Size: 5µ Figure 2. Standard Sound Attenuator Insulation: helical wire. The nylon cloth is porous to air but will not allow fiberglass particles to pass through it. The outer jacket is made of two-ply reinforced reflective mylar; providing a vapor seal to prevent leakage and moisture migration, and increases the insulation factor by reducing the radiant heat transfer. Fiberglass blanket insulation fills the void between the jacket and the nylon core. The standard duct has one insulation layer 0.75 inch (19 mm) thick; the R4 duct insulation layer is 1.0 inch (25 mm). The R6 and R8 duct both have two layers of insulation and a double vapor seal; The R6 total insulation thickness is 1.5 inches (38 mm) and R8 total insulation thickness is 2.0 inches (51 mm). Installation Fiberglass Vapor Barrier: Reinforced Aluminized Mylar Min. Pressure: negative 0.5-inch w.c. (125 Pa) Max. Pressure: 4.0 inches w.c. (1000 Pa) Max. Velocity: 5000 ft/min (25 m/s) Min. Length: 3 ft (0.9 m) Max. Length: none Support Distance: every 6-ft (2 m) Min. Inside Bend Radius: 6 inch (150 mm) R-Factor: see Table 2 Table 2. Duct R-factor Outside Dia, Model inch (mm) UPC-26C 3.5 (89) UPC-26CR4 4.0 (102) UPC-26CR6 5.0 (127) UPC-26CR8 6.0 (152) R-factor F-hr-ft2/Btu Rated* Effective** * per ADC Flexible Duct Standard, based on flat thickness, k=.24 Btu-in/h ft2 F ** per ASHARE 2001 Fundamentals Handbook p , based on curved thickness For complete installation instructions refer to Bulletin UnicoSystem Measured Sound Pressure Level in Occupied Space Whenever duct is installed in an unconditioned space, the heat gain and loss calculations must include duct loss. Table 1 shows the recommended values for the different sound attenuator models. These are based on both thermal losses and losses due to leakage for a typical installation. Table 1. Recommended Duct Loss (includes leakage) Season Cooling* Heating** Conventional Duct Unico Duct, UPC-26C -R4 -R R8 3 6 * Based on 120 F surrounding temperature ** Based on 10 F surrounding temperature The R-factor is calculated per the Air Diffusion Council (ADC) Flexible Duct Standard. This code assumes that the duct wall is flat. This assumption works well for conventional ducts because the duct radius is usually quite large. However, for small ducts, assuming the duct wall is flat overestimates the thermal losses. Therefore, the R-factor specified for a small duct may be less than the value required for a conventional duct. This is described as an equivalent R-factor in Table 2 and is further explained in National Evaluation Service, Inc. (NES) Report Number NER-A Copyright 2003 Unico, Inc. OCTAVE BAND SOUND PRESSURE LEVEL, db re 20 µ Pa Duct Heat Gain/Loss without Attenuator (Aluminum core only) 50 NC NC NC-35 with Attenuator NC NC-30 Measured 8 from outlet in 13 x 8.5 typical office. Tested 8/18/ k 2k 8k 4k R OCTAVE BAND CENTER FREQUENCY, Hz 11/23/94 Figure 3. Sound Pressure Data

50 Bulletin / June 1999 Rigid Sound Attenuator Application The Unico System rigid sound attenuators are designed for closecoupled applications where it is desired to attach the outlets as close as possible to the plenum. They are ideal for older, historic buildings and churches, where the plenum may be located along the wall with the outlets pointed up or down. They are also well suited for masonry or concrete structures with no ceiling joists or a 12.0 in (30 cm) General The Unico System rigid sound attenuator tubing is supplied in 12- inch (30-cm) lengths and is sold in kits (UPC-84, 85) that include all of the necessary components to install an outlet branch run. The attenuator may be cut to any length but not less than 8-inches (20 cm). Figure 2 shows a typical center hall installation for both wood and masonry construction. After the duct system has been installed, a false ceiling can be constructed to conceal it. Figure 3 shows a typical under-slab installation. A PVC coated spiral duct must be used to prevent the deterioration or corrosion of the buried ductwork. Use a floor screen (UPC-88) to prevent object from falling into duct and blocking airflow. Since the outlet is much shorter than normal, they will deliver approximately 50 per cent more air than a normal full outlet. The increased airflow will allow fewer outlets to be used but the sound level will increase. If increased sound levels are not important, use 4 outlets per ton. Otherwise, it will be necessary to add a 15% balancing orifice on each plenum takeoff using 5 outlets per ton. For installation instructions refer to Bulletin Figure 1. Rigid Sound Attenuator IL00094.CVS crawl space. In those cases, a plenum may be routed down the center of a hallway/corridor with the outlets connected directly to the plenum and discharging into the conditioned space next to the hallway/corridor. The rigid attenuators and plenum may be boxed in for appearance. However, in some cases such as large auditoriums or restaurants the duct system may be left exposed and painted or covered for appearance. In these cases the terminator can be replaced with a tape ring (UPC-39) to dress up the outlet end of the rigid attenuator. The rigid attenuators are also designed for under-slab installations. CONCRETE GRAVEL/SAND EARTH UPC-85 Short Attenuator Assy 4" PVC or PVC Coated Spiral Duct 8" Min Metal Takeoff (w/ gasket) 7" to 4" Saddle Collar 7" PVC Coated Spiral Duct Figure 3. Typical Slab Installation IL00095.CVS Terminator (UPC-56B) Short Attenuator Tape Ring Plenum Existing Ceiling 8.0 to 12.0 inches (20 to 30 cm) Caulking Plastic Tubing 2.0" O.D. Drywall Frame Balancing Orifice (optional) False Ceiling Plenum Takeoff (UPC-23B or UPC-28) Concrete or Brick Stud Wall Construction Masonry Construction Figure 2. Typical Center Hall Installation Note Specifications, ratings, and dimensions subject to change without notice. IL00089A.CVS Copyright Unico, Inc.

51 Bulletin / February 2004 UPC-66, UPC-67A, and UPC-68 Slotted Outlets Parts included: (1) insulated slotted outlet (90º or straight) (1) decorative trim plate with fasteners (1) mounting bracket and rails (UPC-66, UPC-67A, and UPC-68) (1) clamp, sound attenuator NOTE: UPC-67 replaced by UPC-67A which includes mounting bracket and rails. Application In addition to the round outlets, Unico also manufactures rectangular outlets. The rectangular outlets feature a narrow width slot that gives a better appearance in a sidewall installation. There are four (4) different types of slotted outlets. The type of outlet not covered by this bulletin is connected directly to the plenum and is described in Bulletin This bulletin covers the three outlet types which are used in conjunction with the Sound Attenuator supply tubing. The Unico System patented 90 slotted outlets (UPC-66 and UPC-67A) are specially designed to quietly turn the air inside a typical wood frame stud wall cavity. The 90º outlets are particularly useful where there is insufficient room to provide the minimum sound attenuator bend radius. Other applications for the 90º outlet include placement near the perimeter of a low-pitched roof, and in applications with only a small cavity between a dropped ceiling and the roof. The UPC-66 is made of cast aluminum and is designed for commercial applications that prohibit the use of plastic ducting. Most applications will use the UPC-67A which is identical to the UPC-66 but made of plastic and intended for residential use. Use of the UPC-66 or UPC- 67A will depend on local code requirements. The Unico System straight slotted outlet (UPC-68) with its patent pending contour shape is designed for use where placement of the standard round outlet is not practical. The straight slotted outlets are particular useful where there is insufficient room for a round outlet at the desired termination point. A typical application for the straight slotted outlet would be placement in a cabinet soffit. The UPC-68 is made of plastic and is intended for residential use. Both the 90 and straight slotted outlets may also be used as ceiling outlets. Specifications Recommended airflow: 15 to 35 CFM Recommended number of outlets: 6 per nominal ton Slotted outlet material: aluminum, cast (UPC-66) plastic, HDPE, black (UPC-67A/68) UL-94 Rating - HB Trim plate material: Plastic, ABS, white, paintable Trim plate part number: A (UPC-66) A (UPC-67A/68) Wall thickness: 3/8 to 3/4 inch (0.95 x 1.91-cm) Size of opening: 1/2 8-inch (13 20-mm) Weight: UPC-66: 2.5 lbs (1.1 kg) UPC-67: 0.8 lbs (0.36 kg) UPC-68: 0.8 lbs (0.36 kg) Mounting bracket length: 14 to 24 inches (356 and 610 mm) Minimum sound attenuator required: 3 ft. (0.9 m) Figure 1. UPC-68 (left) and UPC-66 Shown with Trim Plate, Mounting Bracket, and Hanger Rails Note Specifications, ratings, and dimensions subject to change without notice. Copyright 2004 Unico, Inc.

52 Bulletin Page 2 swing out at the bottom. Use the second set of hanger rails to act as a stop at the location of the tape ring. Position the hanger rails so the outlet discharge will be square with the dry wall once it is installed. 7.5 in (18.4 cm) UPC-67-BRKT UL 181A Tape UPC-26C Tubing Figure 2. Typical Wall Installation, 90º Outlet 3.5 in (8.9 cm) Cut Out Opening IL00364.CVX Installation Location: For wall installations the slotted outlet should be located high on the wall above head height and a minimum of 5-inches (13-cm) below the ceiling. For ceiling installations locate it a minimum of 4-inches (10- cm) away from the adjacent wall. Note: The plastic outlets are shipped with a Styrofoam plug, REMOVE the plug before the trim plate is installed. Mounting: For new construction, mount the outlet between the joists with the tip of the outlet protruding 0.50 inches (12 mm) beyond the joists. For existing construction, you must cut an opening large enough to fit the outlet from either the front or backside of the wall. The minimum size opening for the 90º outlets is 5-inches high 9.75-inches wide ( mm). The minimum size opening for the straight outlet is 3.5-inches high inches wide ( mm). You will need to cut a larger opening to use the mounting brackets for both types of outlets. 5 in. (13 cm) Cut Out Opening Second Hanger Bar IL00360.CVX UPC-67-BRKT 7.25 in (18.4 cm) UL 181A Tape UPC-26C Tubing Figure 3. Existing Wall Cut-out Opening, 90º Outlet Figures 3 and 4 show typical wall installations. Insert one of the hanger rails in the slotted channel on the backside of the mounting plate. Expand the hanger rails to reach the studs and nail securely so the mounting plate will be flush with the backside of the dry wall when it is installed. The UPC-66 and UPC-67A have a tendency to Figure 4. Existing Wall Cut-out Opening, Straight Outlet Special Instructions for Humid Conditions: Anytime the outlets are located in a humid space, be sure to wrap the exterior of the outlet with at least 1-inch (25-mm) of additional fiberglass blanket insulation or use a polyurethane foam spray equivalent to an R-4. The UPC-66 should not be used in areas of high humidity. As an option to the UPC-66, the UPC-67A is recommended for use in humid spaces with the additional R-4 equivalent insulation. Connecting to Duct: Connect a minimum of 3 feet (0.9 m) of sound attenuator (UPC-26C) to the outlet using a clamp (UPC-53) and UL-181-A or UL-181-B listed tape. Be sure to provide the proper bend radius for the tubing. UPC-67 Alternative Mounting Instructions: As an alternative to the supplied mounting bracket, the UPC-67 is light enough to secure to any cross member or stringer using sheet metal screws. Metal duct drives can also be used to hold the outlet in place. Installing the Trim Plate: Once the outlet and ducting is in place, hang the interior wall, cutting a rectangular hole for the tip of the outlet to protrude. The size of the hole is different for the UPC-66 and UPC-67/68 because they have different trim plates. The size of hole to cut for each outlet is listed in Table 1. The UPC-66 trim plate fits around the tip of the outlet, whereas the UPC-67 and UPC-68 trim plates fit inside of the outlet. Table 1. Rough-In Hole Size Model Rough-in Size of Slot UPC inches ( mm) UPC inches ( mm) UPC x 9.25 inches (25 x 235 mm) The UPC-66 ships with a removable cardboard ring you can use as a spacer to maintain proper clearance for the trim plate when you patch the wall. No extra clearance is required for the UPC-67A or the UPC-68. Leave the Styrofoam plug in place while patching the wall to maintain the shape of the outlet. The trim plate mounting fasteners are supplied with the outlet. The UPC-66 includes two screws and the UPC- Copyright Unico, Inc.

53 Bulletin Page 3 67A and UPC-68 include two screws and toggles. When installed properly, the trim plate and the outlet mounting plate will sandwich the wall. Once installed, you can paint the trim plate if desired. 1.75" 0.63" 10.35" 9.10" Opening Sizes UPC-66: 0.85X8.35-in. (2.16X21.2-cm) UPC-67/68: 0.64X8.12-in (1.63X20.6-cm) Figure 5. Trim Plate Dimensions Ceiling Mount Special Installation: Install the tubing parallel to attic rafters to prevent any sharp bends in the tubing run near the outlet unless there is room to have at least a 6-inch (15-cm) or more radius for the tubing connected to the outlet (see Figure 3). For dropped ceilings, extend the hanger rails the width of the ceiling tiles. UPC-26C Attic Rafters Tubing Run 4-in. (10-cm) UPC-66 Wall 0.88" IL0632.CVX walls and floor. Each outlet was installed with 3-feet (0.9-m) sound attenuator tubing. It is considered to be the worst case (i.e. loudest) situation. The sound pressure levels were taken at a distance of 3 feet (0.9-m) from the outlet. Table 2 lists Noise Criteria (NC) and A-Weighted sound levels (dba) for each outlet operating at 35 CFM. Table 2. Sound Rating Data Outlet Type Noise Criteria (NC) A-Weighted Sound Level (dba) Straight Slotted Outlet NC30 38 dba 90º Aluminum Outlet NC30 35 dba 90º Plastic Outlet NC25 38 dba Round Outlet With Screen NC30 35 dba Round Outlet Without Screen NC25 33 dba Sound Pressure Level, db re 20 µpa Threshold of Audibiliyt Octave Band Center Frequency, Hz 1k 2k UPC-66 Measured 3 ft. (1 m) from unit 12 X 45 ft. Hall Tested 2/9/2004 4k 8k NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC-25 NC-20 NC-15 Min 6-in. (13-cm) Radius UPC-26C Attic Rafters UPC-66 Figure 6. Existing Ceiling Installation Commissioning Always verify the airflow before the outlet is completely enclosed. Check airflow with a TurboMeter positioned at the center of the outlet (see Figure 7). Using the knots reading to find the airflow rate from the tables on the following page or for the 90º outlet, multiply the value by 4, then add 4 and for the straight outlet, simply multiply the knots reading by 6. For example, if the TurboMeter indicates 7 knots for the 90º outlet, this would be (7 4) + 4 = 32 CFM. If the TurboMeter reads 5.5 knots for the straight slotted outlet this would be = 33 CFM. Equations for these calculations are listed below or use the tables on the following page. (Multiply CFM by to obtain L/s.) Flow rate calculations for slotted outlets: 90º Outlet: (Knots 4) + 4 = CFM Straight Outlet: Knots 6 = CFM Acoustical Data The sound data presented in this bulletin was measured in a large reverberant hall with hard surfaces for the IL00358.CVX Sound Pressure Level, db re 20 µpa Sound Pressure Level, db re 20 µpa Measured 3 ft. (1 m) from unit 12 X 45 ft. Hall Tested 2/9/2004 NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC-25 NC-20 Threshold NC-15 of Audibiliyt Octave Band Center Frequency, Hz 1k 2k UPC-67A 4k 8k Measured 3 ft. (1 m) from unit 12 X 45 ft. Hall Tested 2/9/2004 NC-60 NC-55 NC-50 NC-45 NC-40 NC-35 NC-30 NC-25 NC-20 Threshold NC-15 of Audibiliyt Octave Band Center Frequency, Hz 1k 2k 4k 8k UPC-68 Copyright Unico, Inc.

54 Bulletin Page 4 Knots Straight Slotted Outlet Airflow, CFM (L/S) TurboMeter knots to Airflow Tables Knots 90º Slotted Outlet Airflow, CFM (L/s) Knots Round Outlet Airflow, CFM (L/s) (9.4) (9.4) (9.4) (9.9) (9.9) (9.9) (10.4) (10.4) (10.4) (10.9) (10.9) (10.9) (11.3) (11.3) (11.3) (11.8) (11.8) (11.8) (12.3) (12.3) (12.3) (12.7) (12.7) (12.7) (13.2) (13.2) (13.2) (13.7) (13.7) (13.7) (14.2) (14.2) (14.2) (14.6) (14.6) (14.6) (15.1) (15.1) (15.1) (15.6) (15.6) (15.6) (16.0) (16.0) (16.0) (16.5) (16.5) (16.5) (17.0) (17.0) (17.0) (17.5) (17.5) (17.5) (17.9) (17.9) (17.9) (18.4) (18.4) (18.4) (18.9) (18.9) (18.9) Figure 7. TurboMeter Placement for Slotted Outlets Copyright Unico, Inc.

55 Bulletin / August 2005 INSTALLATION MANUAL M1218 FAN COIL NOTICE TO INSTALLER AND EQUIPMENT OWNER: RETAIN THIS MANUAL AT THE JOB 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 System Sizing and Layout bulletin. SUFFICIENT BUILDING INSULATION IS ESSENTIAL FOR THE MOST ECONOMICAL OPERATION TABLE OF CONTENTS INTRODUCTION... 1 UNPACKING... 2 LOCATION... 2 SECONDARY DRAIN PAN... 3 MOUNTING... 4 Horizontal Platform... 4 Horizontal Suspended... 4 Ceiling... 4 Vertical... 5 DUCT CONNECTION... 5 Supply Plenum... 5 Return Duct... 5 PIPING... 6 Condensate Lines... 6 Refrigerant Lines... 7 Expansion Valve... 7 Water Connections... 8 WIRING... 8 CHARGING AND STARTUP... 9 Sequence of Operation... 9 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 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 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. Il00159.CV5 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. C CM US CERTIFIED TO UL STD 1995 CONFORMS TO CAN/CSA STD C22.2 NO. 236 Copyright 2005 Unico, Inc.

56 OU T IN Bulletin Page 2 Heating Only Blower Cabinet + Hot Water Coil) Cooling Only Blower Cabinet + Cooling Coil Heating and Cooling Blower Cabinet + Hot water Coil + Cooling Coil Horizontal Flow Vertical Up- Flow Figure 1. Unit Arrangement IL00148.CV5 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 shipping and are carefully packaged in individual cartons. Inspect all cartons prior to CARDBOARD SUPPORTS unpacking. Notify carrier of any damage. Open the carton to remove the unit. 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 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 zero 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. Figure 2. Location of Motor Shipping Supports Copyright 2005 Unico, Inc.

57 Bulletin Page 3 1 (25) Minimum Supply plenum 1(25)Minimum Supply Plenum Supply plenum Air Flow Air Flow Air Flow Side View Top View 38 " 38 " 24(610) side clearance for service Suspended Installation Side View 18 (457) bottom clearance for service 38 " 12 " 20 " 12 " Return Duct Return Duct Return Duct Position the return air 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 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 joists 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 Model Return Air Box Part No. Size of opening inches (mm) All dimensions in inches (mm). Figure 3. Minimum Clearances IL00149.CV5 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. 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 UPC ( ) 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. Plenum Adapter (UPC ) Control Panel Blower Cabinet Cooling Coil Heating Coil Return Air Adapter (UPC ) Q-Band and Q-Clip Return Air Duct (UPC ) Isolation Pads Secondary Drain Pan (UPC 94 ) Platform Figure 4. Typical Horizontal Attic Installation, M1218 For10foot(3.6m)ReturnDuct Do not exceed 100 inches (2.5 m) Return Air Box (UPC ) Q-Band and Q-Clip IL00150.CV5 Copyright 2005 Unico, Inc.

58 Bulletin Page 4 Table 2. Secondary Drain Pan Unit Size Part No. M1218 UPC 94 Dimensions inches (mm) 40 x 22 (1016 x 559) NOTE The drain fitting extends 7/8 inch (22 mm) beyond this dimension. 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 be taken to assure proper drain line pitch. The platform height must allow for proper pitch of the condensate drain lines at least ¼ inch drop per lineal foot (20 mm per meter). The platform can be built from a sheet of ½ 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 3. Horizontal Distance of Drain Piping for Different Framing Materials Frame Lumber: 2 x 4 2 x 6 2 x 8 2 x 10 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 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 Max. Horizontal Run, ft. (m) 18 (5) 26 (8) 34 (10) 42 (13) The platform size should be a minimum of 22 x 40 inches (559 x 1016 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. Figure 6. Typical Horizontal Suspension Mounting or wires. Adjust the straps or wires to pitch the secondary drain pan toward the drain connection. Ceiling Mounting Joist Ceiling Mounting Rails IL00164.CV5 Figure 7. Typical Ceiling Mounting Unit Metal Straps or Wires Secondary Drain Pan Figure 5. Typical Platform Installation 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. 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. Copyright 2005 Unico, Inc.

59 Bulletin Page 5 Vertical Rail Mounting The unit can only be mounted in the 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). 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 unit is completed. Unit Mounting Board (temporary) DUCT CONNECTION Wall 6 x 5 16 IL00171.CV5 Figure 8. Screw Hole Pattern of Mounting Mounting Rail (UPC-95) Il00162.Cv5 Figure 9. Typical vertical Rail Mounting 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) diameter duct. The M1218 plenum adapter (UPC ) 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 separate bulletin for the installation of the ductwork. A 6-in plenum can be used so long as a 7-in duct is 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. Blower Cabinet Plenum Insulation Wrap Plenum Adapter Figure 10. Plenum Adapter Installation IL00155.CV5 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. 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 ½- in (125 x 150, 100 x 190 mm). The square 6 ½ x 6 ½-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, and 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 Copyright 2005 Unico, Inc.

60 Bulletin Page 6 (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; 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 ). 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 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) ¼-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 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. Elevate the unit so the condensate lines are pitched at least ¼ 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 condensate 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. 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 53/8 (137 mm) 21/4 (57 mm) Pitch ¼ inch per foot (2 cm per m) FRAMING Optional Condensate U-TRAP (A00924) Figure 12. Typical Condensate Trap IL00154a.CV5 RETURN AIR BOX FILTER FRAME FILTER FILTER GRILLE IL00153.CV5 Figure 11. Return Air Box and Filter 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 pressures. The U-Traps also feature easy to remove clean-out caps and Copyright 2005 Unico, Inc.

61 IN OUT Bulletin Page 7 Switch Paper Fuse Location of Paper Fuse Indoor Terminal Block Switch Leads Il00156.Cv5 Condenser Il00157.CNV Figure 13. Wiring Diagram for Paper Fuse R Y sight glass should also be installed between the filter-drier and expansion valve near the indoor unit (see Fig. 14). 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: 1. Remove plastic caps to external 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. 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. The refrigerant lines are copper sweat connections. The liquid line is 3/8 inch (9.5 mm) OD and the suction line is 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 Expansion Valve Seal Plate Liquid Line Distributor CAULK (TOP & BOTTOM) External Equilizer Line Suction Line Bulb Figure 15. Expansion Valve Location OUTLET Il00170.CV5 EVAPORATOR COIL GAS (SUCTION) ACCESS PANEL AIRFLOW TXV SIGHT DRIER LIQ. GLASS FROM CONDERSER INLET Il00168.CV5 AIR Il00161.Cv5 Figure 14. Refrigeration Schematic Figure 16. Hot Water Coil Connection Copyright 2005 Unico, Inc.

62 Bulletin 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. Refer 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. 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. 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 will ship with that the electric duct heater. 1. Connect the control wiring per Fig. 19 for cooling-only application, Fig. 20 for heat pump applications, or Fig. 21 for cooling with a hot water coil. Refer to Installation Instructions for Electric Duct Heaters for wiring instructions for auxiliary heaters. NOTES UNICO SYSTEM M1218 L1 L2 COIL COIL EQUIPT. GROUND TYPICAL THERMOSTAT HEATING W COMMON X POWER R REV. VALVE B (HEATING) REV. VALVE O (COOLING) COMPRESSOR Y FAN G (SEE NOTE 1) 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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 USED FOR HEAT PUMP VER- SIONS ONLY. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COILS. 5. THEMOTORMAYBE2OR3-SPEED. BR BR BK BU BK BK VENT DRAIN FOR COOLING ONLY INSTALLATIONS, OMIT ITEMS MARKED YE FAN RELAY Figure 18. M1218 Electrical Wiring Diagram BK BU RD PR BK TO BOILER FROM PUMP/BOILER YE YE OR COM BR BR MOTOR (SEE NOTE 5.) Il00176.Cv5 Figure 17. Water Piping Schematic BOILER \ WATER HEATER 24V TRANSFORMER RD 208V (SEE NO TE 2) BU 230V TYPICAL OUTDOOR SECTION W DEFROST HEAT C COMMON R POWER REV. VALVE COMPRESSOR AFS ANTI-FROST CONTROL (SEE NOTE 4) WARNING! BE SURE TO INSULATE THE UNUSED TRANSFORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. O Y BR BR WIRING LEGEND FACTORY FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 Copyright 2005 Unico, Inc.

63 Bulletin 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! BE SURE TO INSULATE THE UNUSED TRANSFORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. 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 FAN HEAT COMPRESSOR POWER G W Y R UNICO SYSTEM AIR HANDLER 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 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 OUTDOOR CONDENSING UNIT Y C COMPRESSOR COMMON Figure 19. Control Wiring Diagram for UNICO SYSTEM Cooling-Only Applications TYPICAL HEAT PUMP THERMOSTAT FAN COMPRESSOR REV. VALVE (COOLING) POWER REV. VALVE (HEATING) COMMON EMER. HEAT AUX. HEAT AUX. HEAT 1 G L Y O R B X E W2 W3 1 UNICO SYSTEM AIR HANDLER OUTDOOR CONDENSING UNIT W O R Y X DEFROST HEAT REV. VALVE POWER COMPRESSOR COMMON WIRING DIAGRAM AS SHOWN IS FOR A REVERSING VALVE THAT IS ENERGIZED IN COOLING MODE. WHEN VALVE IS ENRGIZED IN HEATING MODE, USE THE "B' TERMINAL ON THE THERMOSTAT, INSTEAD OF THE "O" TERMINAL. Figure 20. Control Wiring Diagram for UNICO Il00174.CVS THERMOSTA Honeywell T T87F Thermostat with Q539A subbase (or equal) POWER COMMON FAN HEAT COMPRESSOR POWER COMMON G W Y Y C R X OUTDOOR CONDENSING UNIT CONTROL WIRING DIAGRAM FOR COOLING ONLY UNICO SYSTEM WITH HYDRONIC HEAT WITH ISOLATED BOILER/PUMP SWITCH UNICO SYSTEM AIR HANDLER Charging and Startup DPDT RELAY Honeywell R8222D1014 or Steveco Relay plus Enclosure (or equal) Sequence of Operation The sequence of operation depends greatly on the options 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 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 thermostat 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 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 Cycle (Heat Pump). Setting the thermostat to HEATING will automatically switch the reversing valve T T AQUASTAT BOILER OR PUMP T T IL00130b.CVS Figure 21. Control Wiring Diagram for Cooling Only UNICO SYSTEM with Hydronic Heat with Isolated Boiler/Pump Switch Copyright 2005 Unico, Inc.

64 Bulletin 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 Cycle (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 deenergizes the fan relay. After about 40-seconds the blower stops. 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 Table 4. Motor Amperage versus Airflow Airflow 230V CFM (l/s) High Speed Medium Speed Low Speed 3-Speed 200 (94) Motor 300 (142) (Standard) 400 (189) Speed 200 (94) * Motor 300 (142) * (Optional) 400 (189) * *Low speed for the optional 2-Speed motor produces half the high speed airflow ( V) 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 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. DS105I07) 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. Copyright 2005 Unico, Inc.

65 Bulletin 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 system pressure drop is 0.25 inches w.c., the total static pressure drop is: = 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 Clear Glass Metal Tube w/ Marks Clear Plastic Tubing To Plenu m Static Pressure Reading (When bubbles just stop.) IL00053.CV5 90 Inside of Plenum AIRFLOW Measuring Tube Plenum Wall End must be flush here IL00051.CV5 To Manometer 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 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. Figure 23. Glass-Bubble Manometer Table 5. Airflow Troubleshooting Chart Problem Probable Cause Remedy Low Static and Low Amperage Low static, high amperage High Static, Low Amperage Blocked filters, restriction in return duct. Low Voltage. Blower Wheel not aligned properly. Large number of outlets or open duct. Restrictive duct system. 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. Add balancing orifices to outlets, check for missing end caps or separated plenum. Add outlets, add splitter vane in tee, reduce the number of tees and elbows in plenum, increase plenum size to 9 equivalent. Copyright 2005 Unico, Inc.

66 Bulletin 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. 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 carefully 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 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. 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 removed 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), superheat 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). Copyright 2005 Unico, Inc.

67 Bulletin 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 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 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 Protocol's next phase-out targets are hydrochlorofluorocarbons (HCFCs), including R-22, the primary refrigerant in residential heating & 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 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. 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. Charging a Heat Pump System Charging in Cooling Mode. Charging a heat pump, by its nature, is 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 because 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. Copyright 2005 Unico, Inc.

68 Bulletin Page 14 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. In heating mode, the Unico System will have a slightly higher discharge (LIQ.) pressure then a conventional system, usually about 30 to 40 psig higher. It is this higher pressure that produces a warmer air temperature; preventing cold blow, where the house is being heated with an air stream that feels cold. Some outdoor heat pump units include a manual highpressure switch. It is important that the system be operated at pressures below the trip pressure of the high-pressure switch to avoid nuisance shut downs. If this occurs, use a high head kit as described below. Using a High Head Kit (Mild Weather Kit). When any heat pump is operated during mild weather (temperatures above 50 F (10 C)), the compressor may trip out on the high pressure limit. The Unico System is particularly sensitive to this since it operates at a higher pressure. To overcome this problem, install a mild weather kit (UPC 65) to cycle the outdoor fan based on the compressor discharge pressure. However, be sure this control is compatible with the outdoor heat pump section being used. Table 6a. R-22 / 410A Saturation Pressure Temperature (English units) psig F R-22 R-410A Table 6b. R-22 / 410A Saturation Pressure Temperature (SI units) kpa (gauge) C R-22 R-410A Copyright 2005 Unico, Inc.

69 Bulletin Page 15 Appendix A Hot Water Coil Performance Entering Water Temperature Water Flowrate Airflow, SCFM (m 3 /s) 200 (0.09) 300 (0.14) 400 (0.19) Capacity Capacity Capacity WPD F C GPM (L/s) MBH (KW) MBH (KW) MBH (KW) ft. water (KPa) 2 (0.13) 10.2 (2.97) 13.7 (4.01) 16.2 (4.76) 0.9 (2.69) 120 (48.9) 4 (0.25) 10.6 (3.10) 14.9 (4.37) 18.5 (5.42) 3.2 (9.57) 6 (0.38) 10.7 (3.13) 15.3 (4.49) 19.3 (5.65) 7.1 (21.23) 8 (0.50) 10.7 (3.15) 15.5 (4.54) 19.7 (5.76) 12.5 (37.38) 2 (0.13) 12.2 (3.58) 16.5 (4.83) 19.6 (5.75) 0.9 (2.69) 130 (54.4) 4 (0.25) 12.7 (3.72) 18.0 (5.26) 22.3 (6.52) 3.2 (9.57) 6 (0.38) 12.8 (3.76) 18.4 (5.40) 23.2 (6.79) 7.1 (21.23) 8 (0.50) 12.9 (3.78) 18.6 (5.46) 23.6 (6.93) 12.5 (37.38) 2 (0.13) 14.3 (4.19) 19.3 (5.66) 23.0 (6.74) 0.9 (2.69) 140 (60) 4 (0.25) 14.8 (4.35) 21.0 (6.15) 26.1 (7.64) 3.2 (9.57) 6 (0.38) 15.0 (4.39) 21.5 (6.31) 27.1 (7.94) 7.1 (21.23) 8 (0.50) 15.1 (4.41) 21.8 (6.38) 27.6 (8.09) 12.5 (37.38) 2 (0.13) 16.4 (4.79) 22.2 (6.50) 26.4 (7.75) 0.9 (2.69) 150 (65.5) 4 (0.25) 17.0 (4.98) 24.1 (7.05) 29.9 (8.75) 3.2 (9.57) 6 (0.38) 17.1 (5.02) 24.6 (7.22) 31.0 (9.10) 7.1 (21.23) 8 (0.50) 17.2 (5.04) 24.9 (7.29) 31.6 (9.27) 12.5 (37.38) 2 (0.13) 18.4 (5.40) 25.0 (7.33) 29.9 (8.76) 0.9 (2.69) 160 (71.1) 4 (0.25) 19.1 (5.60) 27.1 (7.94) 33.7 (9.88) 3.2 (9.57) 6 (0.38) 19.3 (5.65) 27.7 (8.13) 35.0 (10.25) 7.1 (21.23) 8 (0.50) 19.4 (5.67) 28.0 (8.21) 35.6 (10.44) 12.5 (37.38) 2 (0.13) n/a n/a 27.9 (8.17) 33.3 (9.77) 0.9 (2.69) 170 (76.7) 4 (0.25) n/a n/a n/a n/a 37.5 (11.00) 3.2 (9.57) 6 (0.38) n/a n/a n/a n/a 38.9 (11.41) 7.1 (21.23) 8 (0.50) n/a n/a n/a n/a 39.6 (11.61) 12.5 (37.38) Minimum Number of Outlets Appendix B Chilled Water Coil Performance Entering Water Temperature Water Flowrate Airflow, SCFM (m 3 /s) 200 (0.09) 300 (0.14) 400 (0.19) Capacity Capacity Capacity WPD F C GPM (L/s) MBH (KW) SHR MBH (KW) SHR MBH (KW) SHR ft. water (KPa) 3 (0.19) 13.6 (3.98) (5.03) (5.77) (5.37) 35 (1.7) 4 (0.25) 14.4 (4.23) (5.53) (6.48) (10.15) 5 (0.32) 14.9 (4.37) (5.86) (6.98) (15.83) 3 (0.19) 11.8 (3.46) (4.38) (5.03) (5.37) 40 (4.4) 4 (0.25) 12.6 (3.69) (4.81) (5.63) (10.15) 5 (0.32) 13.0 (3.81) (5.10) (6.06) (15.83) 3 (0.19) 10.0 (2.92) (3.69) (4.27) (5.37) 45 (7.2) 4 (0.25) 10.6 (3.10) (4.05) (4.75) (10.15) 5 (0.32) 11.0 (3.21) (4.28) (5.10) (15.83) 3 (0.19) 8.0 (2.34) (2.99) (3.49) (5.37) 50 (10.0) 4 (0.25) 8.5 (2.48) (3.25) (3.84) (10.15) 5 (0.32) 8.8 (2.56) (3.42) (4.09) (15.83) 3 (0.19) 6.0 (1.75) (2.30) (2.72) (5.37) 55 (12.8) 4 (0.25) 6.2 (1.83) (2.44) (2.93) (10.15) 5 (0.32) 6.4 (1.88) (2.53) (3.07) (15.83) Minimum Number of Outlets Copyright 2005 Unico, Inc.

70 Bulletin Page 16 Appendix C Engineering Specifications Construction Dimensions, inch (mm): 12 H x 20 W x 38 L (31 x 51 x 97) Cabinet Type: Galvanized or Painted (P option) Insulation: 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) Unico Part No. 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 3-speed* A Size, hp (kw): 1/3 (0.25) Running rated airflow: 1650/1350 RPM 1700/1550/1350 FLA: RLA: Refer to Amperage Chart Bearing Type: Permanently Lubricated Ball Blower Wheel A Airflow, CFM (m 3 /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) A Nominal Capacity, tons (kw): 1 to 1.5 (3.5 to 5.3) Rated Airflow, CFM (m 3 /s): 450 (0.212) Min. Airflow, CFM/ton (m 3 /s kw): 200 (0.027) Refrigerant Type: R-22 Face Area, ft² (m²): (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 (2.540 x 1.588) Tube Diameter, in (cm): 3/8 (0.953) Tube Type: Rifled Expansion Device (AC option) TXV with Bleed Port A Expansion Device (HP option) TXV with Bleed Port and Internal Check Valve A Liquid Line Connection 3/8 (.953) Suction Connection OD, in. (cm) 5/8 (1.588) Hot Water Coil (HW option) Fluid Type Water or Glycol-Water Solution Face Area, ft² (m²) 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) Fluid Type Water or Glycol-Water Solution Face Area, ft² (m²) (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 (2.540 x 1.588) Tube Diameter, in (cm): 3/8 (.953) Connection OD SWT, in (cm): 5/8 (1.587) HW-1218 A00397-G01 * 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 2005 Unico, Inc.

71 Bulletin / April 2005 INSTALLATION MANUAL FOR M SERIES MODULAR AIR HANDLER UNITS 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 M Series modular air handler units. For heat pumps, refer to Bulletin for additional instructions. Installation instructions for the air distribution system are covered in Bulletin Before beginning any installation a detailed system layout must be done in accordance with the System Sizing and Layout Procedure, Bulletin and the Component Layout Instructions, Bulletin 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 Underwriters 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. The unit is safety certified to UL 1995 and listed 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 indicates the latest revision. 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 process of aspiration produces a more even temperature distribution in the room. TABLE OF CONTENTS INTRODUCTION... 1 OPTIONS... 2 UNPACKING... 2 LOCATION... 3 UNIT ASSEMBLY... 4 Anti-Frost Switch Wires... 4 Fastening Modules Together... 4 Horizontal Installation... 4 Vertical Installation... 4 Control Box... 6 Secondary Drain Pan... 6 MOUNTING... 7 Horizontal Platform Mounting... 7 Horizontal Suspended Mounting... 7 Vertical... 7 DUCT CONNECTIONS... 8 Supply Plenum... 8 Return Duct... 9 Multiple Returns... 9 PIPING... 9 Condensate Lines... 9 Refrigerant Lines Water Connections WIRING STARTUP Sequence of Operation Checking Airflow Charging the System Low Ambient Control Kit R-410A Refrigerant Maintenance Module Configuration Illustrations Specifications Copyright 2004 Unico, Inc.

72 Bulletin Page 2 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, verticalcounter-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. Each module is available in three sizes: 2430, 3642, and 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 cooling 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 23 and 24). Heating-only systems require the blower module, the heating module, and a hot water coil. Coolingonly systems include the blower module and a cooling module. For heating and cooling 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 that 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 additional features or to simplify installation. These include 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 carefully 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 responsibility of the consignee to file any claims with the delivering carrier for materials received in damaged condition. Heating Only Cooling Only Heating and Cooling Horizontal Flow Vertical Up-Flow Blower Module` Spacer Module Cooling Module Vertical Plenum Module (without Hot Water Coil) Vertical Plenum Module (with Hot Water Coil) Vertical Counter-Flow Heating Module (with Hot Water Coil) Spacer Module Normal Air Inlet/Outlet Optional Air Inlet IL00010c.CVN Figure 1. Basic Module Arrangement (refer to detail figures shown on Pages 23 and 24) Copyright 2004, Unico, Inc.

73 Bulletin Page 3 5 (127) Minimum for Control Box Cover Removal Table 1. Return Air Box Opening Optional Control Box Placement Air Flow 1 (25) Minimum Side View Return Duct Models Return Air Box Part No. Size of opening inches (mm) 2430 UPC ½ ( ) 1 (25) Minimum Supply Plenum MBxxxxx MCxxxx MHxxxxx 3642 UPC ( ) Secondary Drain Pan 4860 UPC ( ) closet, a bathroom, or any normally unoccupied space. 1 (25) Minimum Supply Plenum Optional Control Box Placement Air Flow All dimensions in inches (mm). Top View MBxxxxx MCxxxx MHxxxxx 6 (152) Minimum 20 (508) side 6 (152) Minimum clearance for service Service clearance: 30 (762) for MH/MC (1067) for MH/MC4860 Figure 2. Minimum Clearances LOCATION Return Duct IL00037b.CNV 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 Duct Layout Design). Provide minimum clearance on both sides for servicing the unit as shown in Fig. 2. The unit can also be installed in a closet, crawlspace, or basement. If the local codes allow, the unit may be installed 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 roof installation requires mounting on blocks with a sheet metal cover or cap to protect the unit from rain and extreme weather conditions. Be sure to position the return air box and filter near the unit allowing at least one 90 bend in the return duct for proper acoustical performance (refer to figure 3 for a typical horizontal attic installation). The section on Return Air Ducts in the manual provides more details. All modules except the MC4860 cooling module are designed to fit through a 14-inch (356 mm) opening, typical of a joist spaced at 16-inch (406 mm) center distance. The MC4860 module requires an 18.5-inch (470 mm) opening. 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 for the return air box is listed in Table 1. If the joists or studs are less than 16-inches (406-mm) centerto-center or running the wrong direction it will be necessary to cut and header the joists. If installing the unit in an attic, avoid placing the unit above a bed. The ideal location is above a central hall, a Control Box Blower Module (MBxxxxx) Cooling Module (MCxxxxx) Heating Module (MHxxxxx) Return Air Adapter (UPC 104-xxxx) Band (supplied with return air box) Plenum Adapter (UPC 61-xxxx) Return Air Duct (UPC-04-xx-1) Isolation Pads Secondary Drain Pan (UPC 20 or 24) Typical 10 foot (3.6 m) Return Duct Use at least one 90 bend. Band Platform Figure 3. Typical Horizontal Attic Installation Return Air Box (UPC-01-xxxx-1) IL00039c.CVS Copyright 2004, Unico, Inc.

74 Bulletin Page 4 UNIT ASSEMBLY The units may be assembled either horizontally or vertically. Refer to Fig. 1 for your particular flow arrangement. 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. Figure Drip-plate installation (horizontal applications only) Latch Hook (shipped loose with MR module) Cooling Module Return Air Plenum or Heating- Module Hook Flange (shipped loose with MR or MH unit) Figure 6. Hook flange location. IL00220a.CNV Figure 4. Module Flange Connection Horizontal Installations IL00009.CVS Most systems are installed in the horizontal configuration, 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 recommended 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). Vertical Installations As shown in figure 1, the modular system can also be configured for vertical up-flow or down-flow. The arrangement 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 1 is included with the MV module (except for the 4860 unit, where it is included with the cooling module). If you are not using the MV module for the 2430 or 3642, you will need to use the Vertical Conversion Kit (UPC-63 or UPC-64) and provide a field fabricated mount for the unit. Copyright 2004, Unico, Inc.

75 Bulletin Page 5 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 cooling module, although the bottom is opening is preferred. The 4860 cooling only has one return opening for either horizontal or vertical applications. The 4860 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 panel from bottom of the coil (bottom of the coil shown). Remove Latches 1 Top panel Move Move 2 Bottom panel 2 Add insulation piece (centered on the panel). Filler Panel (Item A) Install first Add insulation piece 1 Trim to fit approx. 1.5 inches (38 mm) IL00301b.CNV STEP 1. (2430 and 3642 only) Remove top and bottom panels and install as shown. Install filler panel (Item A) first, then the side panel (1) as shown. Trim insulation as shown. Copyright 2004, Unico, Inc.

76 Bulletin Page 6 Cooling Module Apply Gasket Tape to Top of Module (ships with MV module) Latch Keeper (shipped loose) Vertical Heating Module Final panel assembly shown. IL00304.CNV Airflow UPC-104-xxxx Return Air Adapter Reposition Latches to sides of Module IL00302.CNV Airflow Latches (shipped loose) Return Air Adapter Note: Attach Latches and Latch keepers to appropriate modules 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 ensure air-tight fit. MV Vertical Heat Module Gasket Tape (Shipped Loose) UPC-104 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. Copyright 2004, Unico, Inc.

77 Bulletin Page 7 Blower Module IL00332.CNV Attach both corner brackets (not used on 4860) Airflow Return Air Adapter Corner Bracket (2 plcs) 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-andcooling system, except that the cooling module is removed 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 is 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 blower 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 installed. 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 wiring.) IL00307.CNV 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 isolation 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 arrangements that use the cooling module, the 2-module drain pans can be used where space permits and the return 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 ½-inch (12.7 mm) larger on each side of the bottom module. For vertical 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 discharge and plenum adapter and still provide a sealed drain pan. Table 2. Secondary Drain Pan Dimensions, inches (mm) Unit Size Part No. 2 Modules 3 Modules Dimensions inches (mm) Part No UPC x 22 (1016 x 559) 2430 UPC 20B 3642 UPC 24B 4860 UPC-24C ( ) ( ) UPC 20C UPC 24C Dimensions inches (mm) ( ) ( ) ( ) UPC-24D 40 x 50 (1016 x 1270) NOTE The drain fitting extends 7/8 inch (22 mm) beyond this dimension. Copyright 2004, Unico, Inc.

78 Bulletin 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 unable to use the UPC-24D because of space limitations, use the UPC-24B under the cooling and heating modules. 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 vertical heat module (with or without the heating coil) and the vertical spacer module. 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 be taken to assure proper drain line pitch. 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 cabinet as this could distort unit. The modules 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 supports. 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. Rafter, Joist or Floor RAFTER HOOK CHAIN * A B IL00036a.CNV UNIT 2 Modules 3 Modules SECONDARY DRAIN PAN Unit A 27 (690) 40 (1000) 27 (690) 40 (1000) ANGLE IRON IL00038b.CVN B 30 (760) 42 (1070) 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 ¼ inch drop per lineal foot (20 mm per meter). The platform can be built from a sheet of ½ 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 3. Horizontal Distance of Drain Piping for Different Framing Materials Frame Lumber: Max. Horizontal Run, ft. (m) 18 (5) 26 (8) 34 (10) 42 (13) 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 configuration. The platform size must allow for the number of modules being used. For dimensions for minimum platform size see Fig. 8. Copyright 2004, Unico, Inc.

79 Bulletin Page 9 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 installed between the supply adapter and the unit. The purpose of the restrictor plate is to eliminate objectionable 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 installing 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 highest 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 CFM per nominal ton (27-34 L/s per nominal kw). Measure the motor amperage and use this to ensure the CFM per nominal ton (27-34 L/s per nominal kw) has been achieved. If elevated sound levels are noticed at the outlets and there is more that 250 CFM 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 airflow-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 Blower Module Restrictor Plate Plenum Insulation Wrap Plenum Adapter Figure 12. Supply Plenum Adapter Installation IL00308.CVX supply adapter. If using sheet metal duct, use three (3) or 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. Dimension, inch (mm) A A B D L B Model, UPC (165) 6 (152) 3.25 (83) 6.38 (162) 7 (178) 12 (305) AIRFLOW (182) (257) 9 (229) 10 (254) 18 (457) Figure 10. Round Supply Plenum Adapter Dimensions Figure 11. Square Supply Plenum Adapters L 1 (25) crimped D IL00286.cnv Figure 13. Restrictor Setting Table 4. Approximate Amperages at Given Airflows Unit Size Airflow, CFM (L/s) * 1250 (590) (470) (380) (470) (420) (380) (330) (280) (280) (240) (190) 1.8 * multiply by 1.1 if 208V for more exact airflow use the chart included with the blower Copyright 2004, Unico, Inc.

80 Bulletin 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 between the unit and filter box to reduce sound transmission 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 returns 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 fabricate 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 is significantly less than 100-inches. The minimum 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 cut 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 mounting the filter grille. See Fig. 14. FRAMING RETURN AIR BOX FILTER FRAME 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 Unit Size Cooling Module Blower Module + Heating Module + Cooling Module 4860 UPC UPC UPC UPC UPC UPC Multiple Returns If more than one return is desired, Unico has designed a return plenum (MR) module. The MR module is available in two sizes: 2430 and 3660, and it includes a central filter. The MR module is 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 , Return 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 ¾- inch (19mm) female pipe thread fitting and the secondary drain pan connection is a ¾-inch (19mm) PVC socket fitting. Elevate the unit so the condensate lines are pitched at least ¼-inch per lineal foot (20 mm per meter). Trap the condensate line near the unit 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. FILTER FILTER GRILLE Figure 14. Return Air Box and Filter IL00048.CNV 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 selection. Attach the proper return duct adapter to either the 5 3/8 (137 mm) Figure 15. Typical Condensate Trap 2 1/4 (57 mm) Pitch ¼ inch per foot (2 cm per m) IL00046.CVS Do not trap the secondary drain line and do not terminate line into the primary drain line. Run secondary drain line Copyright 2004, Unico, Inc.

81 Bulletin Page 11 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. 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 purposes. It can also be used to check for leaks prior to installation. Unscrew the Schrader cap and press the depressor. 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 exchange. If pressure is present, then go ahead and relieve the pressure in the coil be continuing to press on the depressor. When all the pressure is removed either cut the ends of the connections off or unbraze the copper caps to prepare for brazing. WARNING To prevent injury, remove all pressure from coil before removing connection end caps. liquid line is 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 information 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. Most refrigerant coils are factory equipped with an R-22 expansion valve mounted on the coil already. For some coils, 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 separately as shown in Table 6. Always use new Teflon seals when replacing the TXV (Unico Part No. A ). Water Connections If you are installing the hot water coil, remove the side CAUTION When brazing, purge with nitrogen gas to prevent the formation of oxides. The refrigerant lines are copper sweat connections. The (a) Hot Water Coil BLEED VALVE (VENT) Table 6. Expansion Valve Model numbers Nominal Valve Part Number Nom. Model Condenser Valve Size R-22 R-410a Size Air-Conditioning Only MC2430C 2 to 2.5-ton (7 to 9 kw) A A to 3.5 ton MC3642C A (10 to 12 kw) A to 5 ton MC4860C (14 to 17 kw) Heat Pump Coils MC2430C 2 to 2.5-ton (7 to 9 kw) A A to 3.5 ton MC3642C A (10 to 12 kw) A to 5 ton MC4860C (14 to 17 kw) IN BLEED VALVE (DRAIN) OUT (b) Chilled Water Coil Figure 16. Water Coil Connections IL00054b.CVN AIRFLOW Copyright 2004, Unico, Inc.

82 Bulletin Page 12 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 connections. Sweat the water connections, then fill the system. 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 is 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, thoroughly and rinsed thoroughly before installation to assure proper drainage of condensate from the coil. This will eliminate blowoff and assure maximum coil performance. 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 components 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 standard 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 ventilation speed is adjustable down to half airflow. The control box includes a 24-volt transformer, the necessary blower relays, and terminal blocks. Space is provided for a heat pump heating mode bypass relay (shipped with heat pump cooling module). Space is also provided for an additional double pole double throw (DPDT) relay for wiring a boiler, pump, or valve if heating 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 Match thermostat anticipator settings for combined amperage load of all components, including electric heater contactors, to prevent damage to thermostat. 4. Connect power supply to terminals L1 and L2 on the high voltage terminal block. Connect a ground wire to equipment grounding on the side of the control box near the incoming power opening. WARNING Be sure to insulate the unused transformer lead to prevent injury or death from electrical shock. The low voltage transformer is factory set for a primary voltage of 230V. If power supply is 208V, remove ORANGE lead from L2 terminal and connect RED lead to L2. Insulate the connector on the unused wire lead. COMPRESSOR IL00255.CNV TYPICAL THERMOSTAT FAN HEAT POWER G W Y R UNICO SYSTEM AIR HANDLER Figure 17. Cooling-only control wiring OUTDOOR CONDENSING UNIT Y C COMPRESSOR COMMON Control Box- Model No. Ventilation Control Availability Wiring Diagram A00175-G02 Yes Standard (U.S., Canada) Fig. 20 A00175-G03 No Special Order (Europe) Fig. 21 Copyright 2004, Unico, Inc.

83 Bulletin Page 13 TYPICAL HEAT PUMP THERMOSTAT UNICO SYSTEM AIR HANDLER OUTDOOR CONDENSING UNIT FAN G 1 L 2 W DEFROST HEAT COMPRESSOR Y 3 REV. VALVE (COOLING) O 4 O REV. VALVE POWER R 5 R POWER REV. VALVE (HEATING) B 1 6 Y COMPRESSOR COMMON X 7 X COMMON EMER. HEAT E Il00062a.CVN AUX. HEAT AUX. HEAT W2 W3 1 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. Figure 18. Heat pump control wiring (without electric heat) THERMOSTAT Honeywell T87F Thermostat with Q539A subbase (or equal) FAN G HEAT W COMPRESSOR Y POWER R COMMON X OUTDOOR CONDENSING UNIT UNICO SYSTEM AIR HANDLER DPDT RELAY Honeywell R8222D1014 or Steveco Relay plusenclosure(or equal) BOILER OR PUMP T T POWER Y 6 COMMON C 7 T T AQUASTAT IL00130c.CVN Figure 19. Cooling with Typical Hot Water Heating control wiring (with optional aquastat) The controller is set at the factory to provide constant ventilation 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 instructions (located near the end of this document). Ventilation Speed Mode The Unico System is 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 control 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 2004, Unico, Inc.

84 Bulletin Page 14 UNICO SYSTEM SERIES M FOR COOLING ONLY INSTALLATIONS, OMIT ITEMS MARKED UNLATCHING RELAY 4 6 BLU YEL BK YEL BLU LO RELAY GRD. LEAD TO MOTOR BASE YEL TYPICAL THERMOSTAT TYPICAL OUTDOOR SECTION V 208V 230V COMMON TO FUSED 230V DISCONNECT NOT OVER 15 AMP FUSE BK RED BK BLU HI RELAY YEL BLU BRN BRN Variable Speed Motor Controller L1 RED BLU L2 BK EQUIPMENT GROUND *Common X Power R *Rev. Valve (Heating) *Rev. Valve (Cooling) B O Compressor Y W O R Defrost Heat* Rev. Valve* Power* *Heating W Y Compressor Fan G C Common BRN BRN ANTI-FROST CONTROL (SEE NOTE 4) 2 4 OR TRANSFORMER 1 3 ANTI-FROST CONTROL BYPASS RELAY (HEAT PUMPS ONLY) (SEE NOTE 3) RED WIRING LEGEND WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FACTORY FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. BLU YEL NOTES 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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 MODULE (MODEL MC2430H, MC3642H, AND MC4860H). FIELD INSTALL RELAY AS SHOWN WHEN USED WITH THESE MODULES. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2430C,H, MC3642C,H AND MC4860C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. A00816.CNV RED RED Figure 20. M Series Electrical Wiring Diagram (with Motor Controller installed) for A00175-G02 Control Box Copyright 2004, Unico, Inc.

85 Bulletin Page 15 UNICO SYSTEM SERIES M BRN BRN RED GRN BLK TYPICAL THERMOSTAT COMMON X POWER R REV. VALVE B (HEATING) REV. VALVE O (COOLING) COMPRESSOR Y HEATING FAN W G (SEE NOTE 1) FOR COOLING ONLY INSTALLATIONS, OMIT ITEMS MARKED W TYPICAL OUTDOOR SECTION DEFROST HEAT O REV. VALVE R Y C POWER COMPRESSOR COMMON TO FUSED 230V DISCONNECT NOT OVER 15 AMP FUSE RED GRN/YEL BLK BRN BRN Fan Relay 1 3 BLK BLK L1 L2 BLK YEL CAPACITOR TRANS- FORMER COMMON ORG BRN BRN BRN 24V RED 208V SEE NOTE 2 YEL BLU 230V BRN BRN BRN ANTI-FROST CONTROL BYPASS RELAY (HEAT PUMPS ONLY) (SEE NOTE 3) ANTI-FROST CONTROL (SEE NOTE 4) NOTES EQUIPT. GROUND 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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 WITH THESE MODULES. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2436C,H AND MC4260C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. WIRING LEGEND FACTORY FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 A00117 Rev. E Figure 21. M Series Electrical Wiring Diagram(without Motor Controller installed) for A00175-G03 Control Box Copyright 2004, Unico, Inc.

86 Bulletin Page 16 For Refrigerant Cooling-Only or Heat Pump systems. Modified to Control Ventilation mode with thermostat FAN switch. Refer to EL00041 if system has hot water heat or EL00046 if system has electric heat. TYPICAL THERMOSTAT *Common X Power R For cooling-only systems, omit items marked *. DWG EL00040 TYPICAL OUTDOOR SECTION FM Unico System SERIES M R R BK BK CR-UN 3 1 BLU BLU *Reversing Valve (Heating) *Reversing Valve (Cooling) B O Compressor Y Fan G Heating (2nd stage) W *Emergency Heat E W O R Y C Defrost Heat* Reversing Valve* Power Compressor Common SC CR-LO G/Y GND. R BK R BR BR BLU BLU CR-HI 3 BR BR AFS (SEE NOTE 4) RC L1 L2 R V 208V COM T 24V EQUIPMENT GROUND R BK BR BR OUTSIDE ELECTRICAL BOX INSIDE ELECTRICAL BOX Y Y (SEE NOTE 1) Y 1 2 TO FUSED 208/230V DISCONNECT NOT OVER 15 AMP FUSE Y BLU OR (SEE NOTE 2) BLU Y BR CR-BP 3 (SEE NOTE 3) BR COMPONENT CODE AFS ANTI-FROST CONTROL SWITCH CR-BP AFS BYPASS CONTROL RELAY CR-HI HIGH SPEED CONTROL RELAY CR-LO LOW SPEED CONTROL RELAY CR-UN UNLATCHING CONTROL RELAY FM FAN MOTOR RC RUN CAPACITOR SC SPEED CONTROL T TRANSFORMER WIRING LEGEND FACTORY LINE VOLTAGE FACTORY LOW VOLTAGE FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. NOTES 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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 BYPASS CONTROL RELAY IS SHIPPED WITH HEAT PUMP COOLING MODULE (MODEL MC2430H, MC3642H, AND MC4860H). FIELD INSTALL RELAY AS SHOWN WHEN USED WITH THESE MODULES. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2430C,H, MC3642C,H AND MC4860C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. This wire is connected to terminal 1 of low voltage terminal box at the factory. Remove and connect to terminal 3 as shown. 1 2 This wire is connected to terminal 5 of low voltage terminal box at the factory. Remove and connect to terminal 1 as shown. Figure 22. Wiring Schematic for Cooling-Only or Heat-Pump without Supplemental Heat (Modified to control ventilation speed mode at thermostat) Copyright 2004, Unico, Inc.

87 Bulletin Page 17 DWG EL00041 TYPICAL THERMOSTAT * Optional *Common X Power R Compressor Y TYPICAL OUTDOOR SECTION *Heating W Y Compressor Fan G C Common BR BR AFS (SEE NOTE 2) (SEE NOTE 3) CR-HTR AQ 4 6 (SEE NOTE 4) COIL TO BOILER OR PUMP OR 230V T BLU R 208V 24V BK COM Y (SEE NOTE 1) NOTES 1. 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. WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. 2. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2430C,H, MC3642C,H AND MC4860C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. 3. EMERGENCY HEAT CONTROL RELAY IS NOT SUPPLIED BY UNICO. RECOMMENDED MODEL IS HONEYWELL MODEL R8222D1014 OR EQUIVALENT DOUBLE-POLE, DOUBLE-THROW RELAY WITH 24V COIL AND CONTACTS RATED FOR LINE VOLTAGE. 4 AQUASTAT IS OPTIONAL. This wire is connected to terminal 5 of low voltage terminal box at the factory. Remove and connect to terminal 1 as shown. For Cooling-Only systems with hot water heat. Modified to Control Ventilation mode with thermostat FAN switch. R R FM Unico System SERIES M CR-UN BLU Y BK Y BK BLU OUTSIDE ELECTRICAL BOX INSIDE ELECTRICAL BOX SC CR-LO Y G/Y GND R BK R BR BR 4 6 BLU BLU CR-HI 3 RC TO FUSED 208/230V DISCONNECT NOT OVER 15 AMP FUSE Y BLU L1 R L2 EQUIPMENT GROUND COMPONENT CODE AFS ANTI-FROST CONTROL SWITCH AQ AQUA-STAT CR-HTR EMERGENCY HEAT CONTROL RELAY CR-HI HIGH SPEED CONTROL RELAY CR-LO LOW SPEED CONTROL RELAY CR-UN UNLATCHING CONTROL RELAY FM FAN MOTOR RC RUN CAPACITOR SC SPEED CONTROL T TRANSFORMER WIRING LEGEND FACTORY LINE VOLTAGE FACTORY LOW VOLTAGE FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 This wire is connected to terminal 1 of low voltage terminal box at the factory. Remove and connect to Emergency Heat Relay as shown. 1 2 Figure 23. Wiring schematic Refrigerant Cooling with Hot Water Heat (Modified to control ventilation speed at thermostat) Copyright 2004, Unico, Inc.

88 Bulletin Page 18 Unico System SERIES M EQUIPMENT GROUND COMPONENT CODE AFS ANTI-FROST CONTROL SWITCH CR-BP AFS BYPASS CONTROL RELAY CR-EM EMERGENCY HEAT CONTROL RELAY CR-HI HIGH SPEED CONTROL RELAY CR-LO LOW SPEED CONTROL RELAY CR-UN UNLATCHING CONTROL RELAY FM FAN MOTOR HTR ELECTRIC DUCT HEATER RC RUN CAPACITOR SC SPEED CONTROL T TRANSFORMER TS OUTDOOR THERMOSTAT WIRING LEGEND FACTORY LINE VOLTAGE FACTORY LOW VOLTAGE FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 TYPICAL THERMOSTAT * optional DWG TYPICAL OUTDOOR SECTION AFS (SEE NOTE 4) HTR CR-EM 4 6 COIL (SEE NOTE 5) T 2 4 CR-BP 1 3 (SEE NOTE 3) WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. NOTES 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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 BYPASS CONTROL RELAY IS SHIPPED WITH HEAT PUMP COOLING MODULE (MODEL MC2430H, MC3642H, AND MC4860H). FIELD INSTALL RELAY AS SHOWN WHEN USED WITH THESE MODULES. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2430C,H, MC3642C,H AND MC4860C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. 5. EMERGENCY HEAT CONTROL RELAY IS NOT SUPPLIED BY UNICO. RECOMMENDED MODEL IS HONEYWELL MODEL R8222D1014 OR EQUIVALENT DOUBLE-POLE, DOUBLE-THROW RELAY WITH 24V COIL AND CONTACTS RATED FOR 24V OR HIGHER TO FUSED 208/230V DISCONNECT NOT OVER 15 AMP FUSE 1 2 (SEE NOTE 1) 2 TS OPEN AT 30 F (-1 C) (SEE NOTE 2) CLOSE AT 20 F (-6 C) Figure 24. Wiring schematic Heat-Pump with Supplemental Electric Duct Heater (second stage) (Modified to control ventilation speed at thermostat) Copyright 2004, Unico, Inc.

89 Bulletin Page 19 TYPICAL THERMOSTAT * optional DWG EL00047 *Common X Power R TYPICAL OUTDOOR SECTION Reversing Valve (Heating) B (SEE NOTE 1) W Defrost Heat Reversing Valve (Cooling) O O Reversing Valve Compressor Y R Power Fan G Heating (2nd stage) W Emergency Heat E Y C Compressor Common BR BR AFS (SEE NOTE 4) AQ CR-EM (SEE NOTE 6) 4 6 COIL (SEE NOTE 5) TO BOILER OR PUMP BR BR OR R BK 230V 208V COM T BLU 24V (SEE NOTE 3) Y BR CR-BP BR (SEE NOTE 2) NOTES 1. IF REVERSING VALVE IS ENERGIZED ON HEATING, CONNECT TERMINAL NO. 4 TO B INSTEAD OF O. 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. WARNING! BE SURE TO INSULATE THE UNUSED TRANS- FORMER LEAD TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. 3. ANTI-FROST BYPASS CONTROL RELAY IS SHIPPED WITH HEAT PUMP COOLING MODULE (MODEL MC2430H, MC3642H, AND MC4860H). FIELD INSTALL RELAY AS SHOWN WHEN USED WITH THESE MODULES. 4. ANTI-FROST CONTROL IS USED ONLY WITH REFRIGERANT COOLING MODULES (MODELS MC2430C,H, MC3642C,H AND MC4860C,H). FIELD ATTACH LEADS TO TERMINALS AS SHOWN. 5. EMERGENCY HEAT CONTROL RELAY IS NOT SUPPLIED BY UNICO. RECOMMENDED MODEL IS HONEYWELL MODEL R8222D1014 OR EQUIVALENT DOUBLE-POLE, DOUBLE-THROW RELAY WITH 24V COIL AND CONTACTS RATED FOR LINE VOLTAGE. 6. AQUASTAT IS OPTIONAL. This wire is connected to terminal 5 of low voltage terminal box at the factory. Remove and connect to terminal 1 as shown. For Heat Pump systems with emergency hot water heat. Modified to Control Ventilation mode with thermostat FAN switch. R R FM Unico System SERIES M CR-UN BLU Y BK Y BK BLU OUTSIDE ELECTRICAL BOX INSIDE ELECTRICAL BOX SC CR-LO Y G/Y GND R BK R BR BR 4 6 BLU BLU CR-HI 3 RC TO FUSED 208/230V DISCONNECT NOT OVER 15 AMP FUSE Y BLU L1 R L2 EQUIPMENT GROUND COMPONENT CODE AFS ANTI-FROST CONTROL SWITCH CR-BP AFS BYPASS CONTROL RELAY CR-EM EMERGENCY HEAT CONTROL RELAY CR-HI HIGH SPEED CONTROL RELAY CR-LO LOW SPEED CONTROL RELAY CR-UN UNLATCHING CONTROL RELAY FM FAN MOTOR HTR ELECTRIC DUCT HEATER RC RUN CAPACITOR SC SPEED CONTROL T TRANSFORMER WIRING LEGEND FACTORY LINE VOLTAGE FACTORY LOW VOLTAGE FIELD (NEC) CLASS 1 FIELD (NEC) CLASS 2 This wire is connected to terminal 1 of low voltage terminal box at the factory. Remove and connect to Emergency Heat Relay as shown. 1 2 Figure 25. Wiring schematic Heat-Pump with Supplemental Hot Water Heat (second stage) (Modified to control ventilation speed at thermostat) Copyright 2004, Unico, Inc.

90 Bulletin Page 20 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 methods are described later in this section. Sequence of Operation The sequence of operation depends greatly on the options 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 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 thermostat 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 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 (Heat 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 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. 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 (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 indoor 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 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 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 G circuit on heating. Ventilation Cycle. When the thermostat is satisfied and the fan switch is set to AUTO, the G circuit is open so that power to the motor goes through the variable 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 thermostat. To turn it off simply move the fan switch to the AUTO position. Checking Air Flow CAUTION Do not operate blower with free discharge or low static pressures (below 1- inch w.c. (250 Pa)) to prevent motor from overloading. After the system is installed and before charging system, check for proper airflow. Record the position of the restrictor plate, the plenum static pressure, and the motor amperage. With this information, the amount of airflow can be determined. Copyright 2004, Unico, Inc.

91 Bulletin Page 21 As a recommended further check on airflow, use a velometer 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. DS105I07) 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 Technote 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 motor 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 that 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 pressure 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 pressure 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: = In this case the static pressure is too high. 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 indicator. 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 from each outlet with a TurboMeter (refer to Tech Note 113, How to Measure Outlet Airflow, for more information). Place the TurboMeter against each outlet, centered as best possible and record the knots. Multiply 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 difference 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 ¼-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, Table 7. Airflow Troubleshooting Chart Problem Probable Cause Remedy Low Static, Low Amperage Restrictor set too low. Blocked filters, restriction in return duct. Low Voltage. Blower Wheel not aligned properly. Dirty blower wheel. Open restrictor to table 4 setting. 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. Clean wheel. Low static, high amperage High Static, Low Amperage Large number of outlets. Restrictor setting to high. Restrictive duct system. 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 number of tees and elbows in plenum, increase plenum size to 9 equivalent, or Open restrictor to proper amperage. Copyright 2004, Unico, Inc.

92 Bulletin Page 22 the reading will be in error. You will get a higher reading if the tube is angled toward the air stream. 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. Figure 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 refrigerant recovery or recycling device. If charging a heat pump, refer to Bulletin 30-24, Instructions for "M" Series Modular Heat Pump Systems. 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 subcooling 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 operating charge in the 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 temperatures, charge the system in the heating mode, but return later when the weather is warmer before the system is switched to cooling. Sub-cooling Method Many condensing unit manufacturers publish the amount of sub-cooling that the condenser 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 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. 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 thermocouple. 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 equation: Saturated Temperature Liquid Line Temperature = Subcooling If the sub-cooling temperature at the condenser is low, the system is undercharged and refrigerant must be added. CAUTION TO PREVENT DAMAGE TO THE COMPRESSOR, DO NOT ADD LIQUID CHARGE INTO SUCTION PORT. Copyright 2004, Unico, Inc.

93 Bulletin Page 23 If it is high, the system is overcharged and some refrigerant must be removed and collected in an empty refrigerant 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 apparent 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, 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), superheat 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). 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 8). 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 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), especially for a 5-ton nominal capacity system. These controls come in different configurations such as the Hoffman Controls Corp. series 800AA-head pressure control. This control modulates the outdoor fan 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 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 Protocol's next phase-out targets are hydro chlorofluorocarbons (HCFCs), including R-22, the primary refrigerant in residential heating & 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 Copyright 2004, Unico, Inc.

94 Bulletin Page 24 of R-22 in 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. 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 is 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 disconnect any module or ducting. To remove the motor and blower wheel assembly, loosen the six (6) screws fastening the motorized blower assembly 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 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 simply 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 blower 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. Table 8a. R-22 / 410A Saturation Pressure Temperature (English units) psig F R-22 R-410A Table 8b. R-22 / 410A Saturation Pressure Temperature (SI units) kpa (gauge) C R-22 R-410A Figure 28. Removal of the Motorized Blower Assembly Copyright 2004, Unico, Inc.

95 Bulletin Page 25 Single Return System Configuration Single Return Fan Only UPC /3642/4860 Heating Module Return Air Adapter UPC Heating Module Return Air Adapter A00557-G01 Spacer Module (shipped with MC4860) MH3660 Heating Module MC4860 Cooling Module 4860 Single Return Heating & Cooling UPC-59B-4860 Cooling Module Return Air Adapter A00557-G01 Spacer Module (shipped with MC4860) MC4860 Cooling Module 4860 Single Return Cooling Only UPC /3642 Heating Module Return Air Adapter MH2430/3660 Heating Module MB2430/3642/4860 Blower Module 2430/3660 Single Return Heating Only HW2430/3660 Hot Water Coil MC2430/3642 Cooling Module UPC-59B-2430/3642 Cooling Module Return Air Adapter 2430/3642 Single Return Cooling Only MH2430/3660 Heating Module UPC /3642 HW2430/3660 Hot Water Coil 2430/3642 Single Return Heating and Cooling 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. IL00316.CNV Figure 29. Horizontal Configuration Chart Copyright 2004, Unico, Inc.

96 Bulletin Page 26 For M2430 and 3642 Units Ensure filler panel is installed Vertical Filler Panel A00556-G01 Spacer Module For M4860 Units Ensure filler panel is removed A00557-G01 Spacer Module MC2430/3642 Cooling Module *A00556-G01 and A00557-G01 are shipped with the MV2430 and MV3642, respectively. The MV4860 is not shipped with an A00557-G01. The MC4860 is shipped with an A00557-G01. MB2430/3642/4860 Blower Module A00556-G01/A00557-G01 Spacer Module* MV2430/3642/4860 Vertical Plenum Module IL00261c.CNV UPC /3642/4860 HW2430 (HW3660) Hot Water Coil Any Hot Water Heating Option Access Panel (shipped with HW2430 or HW3660) or MC4860 Cooling Module Airflow Remove Latches Bottom Panel Vertical Filler Panel Top Panel Airflow Airflow For Multiple Return Systems MR2430 (MR3660) Multiple Return Module UNICO SYSTEM Vertical Installation Remove Drip Plate Airflow Figure 30. Vertical Configuration Chart Copyright 2004, Unico, Inc.

97 Bulletin Page 27 Blower Module Specifications Model No. MB2430L MB3642L MB4860L Motor Electrical Characteristics Volts / 60 / 1 phase Size, HP (kw) 1/2 (0.37) 1 (0.75) 1 (0.75) Full Load Amps Capacitor, mfd Speed, RPM Blower Wheel Nom. Diameter, in. (mm) 9.5 (241) 9.5 (241) 9.5 (241) Blower Wheel Width, inch (mm) 3.75 (95) 5.0 (127) 7.75 (197) Nominal* Air Flow Rate, cfm (L/s) 600 (283) 1000 (472) 1250 (590) Plenum Static Pressure, iwc, (Pa) 1.5 (373) 1.5 (373) 1.5 (373) Sound Pressure Level db(a) NC Minimum Plenum Size, ID, inch (mm) 7 (178) 9 (229) 10 (254) Shipping Weight, lb (kg) 62 (28) 72 (33) 72 (33) Overall Dimensions, in. (mm) H x W x D 17.5 x 25 x (445 x ) 17.5 x 38 x (445 x 965 x 349) Refrigerant Cooling Module Specifications Type of System Cooling Only Heat Pump Model No. MC2430C MC3642C MC2430H MC3642H Compatible Condenser Size, Ton (kw) (7 8.8) ( ) (7 8.8) ( ) Evaporator Coil Net Face Area, ft 2 (m 2 ) 2.13 (0.20) 3.48 (0.32) 2.13 (0.20) 3.48 (0.32) Tube diameter, in. (mm) 3/8 (9.5) Number of rows 4 6 Fins per inch (m) 14 (551) 15.5 (610) Suction line O.D., in. (mm) 7/8 (22.2) Fin Type lanced corrugated Number of Circuits Valve, R-22/R-407C, Part No. A A A A Valve, R-410A, Part No. A A A A Liquid line, in. (mm) OD 3/8 (9.5) Condensate Connection, in. (mm) FPT 3/4 (19) Refrigerant R-22, R-407C, R-410A* Coil Shipping Weight, lb. (kg) 60 (28) 78 (35) 60 (28) 78 (35) Factory Installed Expansion Device TXV TXV with internal Check Valve Overall Dimensions, inch (mm) * R-410A TXV ordered separately H x W x D 17.5 x 25 x (445 x ) 17.5 x 38 x (445 x 965 x 349) 17.5 x 25 x (445 x ) 17.5 x 38 x (445 x 965 x 349) Type of System Cooling Only Heat Pump Model No. MC4860C MC4860H Compatible Condenser Size, Ton (kw) 4-5 ( ) Net Face Area, ft 2 (m 2 ) 7.44 (0.69) Tube diameter, in. (mm) 3/8 (9.5) Number of rows 3 4 Fins per inch (m) 14 (551) Evaporator Suction line, in. (mm) OD 7/8 (22.2) Coil Liquid line, in. (mm) OD 3/8 (9.5) Fin Type lanced corrugated Number of Circuits 8 10 Valve, R-22, Part No. A A Valve, R-410A, Part No. A A Condensate Connection, in. (mm) FPT 3/4 (19) Refrigerant R-22, R-407C, R-410A* Coil Shipping Weight, lb. (kg) 88 (40) Factory Installed Expansion Device TXV TXV with internal Check Valve Overall Dimensions, inch (mm) H x W x D without spacer 17.5 x 25 x 18 (445 x 635 x 457) With spacer 17.5 x 25 x 24 (445 x 635 x 610) * R-410A valve ordered separately Copyright 2004, Unico, Inc.

98 Bulletin / May 2005 Plenum Take-Off Installation Instructions Fiberglass Plenum: Tools required: INSTALLATION 2-inch fiberglass hole cutter ( cookie cutter ), Unico Part no. UPC-55. Utility knife The Spin-in Take-off (Unico part No. UPC-23) is designed for 1-inch (25 mm) thick fiberglass plenum. The plenum can be either 1-inch rigid round duct or 1-inch ductboard. STEP 1. Use the "cookie" cutter to make a neat 2-inch (51 mm) hole in the plenum (Fig. 1). It may be necessary to first cut the outside jacket with a utility knife to prevent tearing of the outside jacket. After the hole is cut, be sure to remove any excess fiberglass in the opening. For square the best position is usually in the side of the duct as shown in Figure 1. Be sure that the bottom flange is fully engaged on the inside of the plenum. It may be necessary to apply some pressure as you spin the takeoff a full 360 around. Inspect the inside of the takeoff for insulation in the air stream. Continue to spin the takeoff until no excess insulation can be seen down inside the stub of the takeoff. Metal Plenum Duct (Preferred Method): The Flanged Take-off (Unico part No. UPC-28) is designed for metal plenum. The plenum can be snap-lock or spiral duct. Tools required: 1 7/8-inch metal hole saw UL-181B duct tape Instructions for installing the Flanged Take-off with metal plenum can be found on the reverse of this page. Figure 4 shows an exploded view of the parts required for this installation. Overlay Gasket Screw Insulation Metal Duct FIG. 1 Tape Ring Takeoff Takeoff Gasket STEP 2. Cut a ½-inch (13 mm) slit in the plenum jacket (Fig. 2). FIG. 4 PLENUM 2in.(51mm)Hole 0.5 in. (13 mm) Slit in Jacket STEP 3. Bend the starting edge of the spin-in takeoff thread flange as shown in Fig. 3. Then twist the spin-in into the hole. Bend flange to start thread FIG. 4 Metal Plenum Duct (Optional): 1. Install and fully insulate the metal plenum before connecting plenum takeoffs. 2. Slit the outer insulation wrap in an "X" pattern about 4 inches across. Then peel the wrap back to expose the duct. 3. Cut a 2-inch (5 cm) hole into the duct and attach Flanged Takeoff (UPC-28) to the duct with selftapping sheet metal screws. Tape Ring Insulation Takeoff Gasket Stub FIG. 3 Tape Ring Gasket Thread Flange IL00092.CVS FIG. 5 IL00093.CVS 4. Smooth out the wrap and seal the "X" with tape. 5. Push tape ring onto stub as far as it will go. Note Specifications, ratings, and dimensions subject to change without notice. Copyright 2005 Unico, Inc.

99 Bulletin / May 2004 Installation Guide Duct Layout Outlets 6 Per Ton (3.5 kw). In order to provide 200 CFM per nominal ton [27 L/s per kw], the average project requires about 6 outlets per nominal ton (1.7 outlets per kw). For hot water heating, refer to performance charts for required total. A full outlet delivers 40 CFM (19 L/s), based on a 10-foot (3 meter) branch duct without any balancing orifices. Be sure to add more outlets to compensate for any outlets less than full. For example, two runs with 50% balancing orifices are equal to one full outlet. 10% Rule. For supply ducts longer than 10 feet (3 meter), the air is reduced in that run by 10% for every 5 feet over 10 (every 1.5 meter over 3 meters). For example, a 30 foot (9 meter) run is 60% of a full outlet (30-10=20 5=4 10=40% Reduction). Consider Traffic Pattern. Place outlets out of traffic pattern. A corner, 5-inch (127 mm) from each wall, is a good location, or along walls, or in soffits blowing horizontally. Consider floor outlets (with screens) for units located in basement. Slotted outlets can be used for high wall locations or in ceilings where there is insufficient room for bending tubing. Allow for Aspiration. Locate outlets so the air stream does not impinge on any objects or people at least 3 feet (1 meter) away. Use outlet deflectors and outlet balancing orifices sparingly as they disrupt the aspiration. Minimize Length, Minimize Restriction. Keep the supply duct length as close to 10 feet (3 meters) as possible and never less than 6 feet (1.8 meters). Use the fewest number of bends as possible. Maximize the radius of any bends making sure the bend in the sound attenuator tubing near the outlet is at least 6-inch (152 mm). Plenum Maximize Length, Minimize Restriction. Run main trunk (plenum) as long as possible; it is better to lengthen the plenum if you can shorten even two outlet runs. Use full flow tees with turning vanes (when applicable) and full flow elbows. The maximum total plenum length is 150 ft (45 meters); consider the first tee equal to 30 ft (9 meters) and elbows equal to 15 ft (4.6 meters). 60/40 Rule. When using a tee split the flow as close to 50/50 as possible no more than 60/40. Always use a turning vane. 70/30 Rule. Turn the tee 90 to make a side branch with no more than 30 percent of the air. Do not use a turning vane Horseshoe Patterns. (Best Method). Use a tee at least 24 inches (610 mm) off unit. For the 4860 unit, use 10- inch (254 mm) metal up to and including tee; then use 9-inch (229 mm) both directions. For the 3642 unit, use 9- inch (229 mm) insulated metal up to and including tee; then use 7-inch (178 mm) both directions. If possible, close the horseshoe into a perimeter loop. IL00121.CVS PERIMETER LOOP SYSTEM HORSESHOE SYSTEM IL00122.CVS DOGLEG SYSTEM IL00123.CVS 'H' SYSTEM IL00125.CVS Note Specifications, Ratings, and Dimensions are subject to change without notice Unico, Inc.

100 Bulletin Page 2 Plenum (cont.) Shotgun Pattern. For the 4860 unit, use 10-inch (254 mm) insulated metal or fiberglass duct for the first 30 percent; then reduce to 9-inch (229 mm) if desired. For the 3642 unit, use 9-inch (229 mm) insulated metal or fiberglass duct for the first 30 percent; then reduce to 7-inch (178 mm) if desired. For the 2430 unit, 7-inch (178 mm) may be run the entire length. 24-inch (610 mm) Rule. Use at least 24-inch (610 mm) of straight plenum before any fitting, such as an elbow, tee, or takeoff or accessory component such as an electric heater. Avoid elbows directly off units. Space Takeoffs Evenly. Maintain distance between takeoffs as evenly as possible. Space the takeoffs at least 6- inch (152 mm) apart and 12-inch (305 mm) from end cap. Sound Sound Attenuators. Always use at least 3 feet (914 mm) of the Unico supplied sound attenuator supply tubing (UPC-26C) at the end of each run. For runs up to 12 feet (3658 mm), you may use the sound attenuator for the entire run. For greater lengths, use the aluminum core supply tubing (UPC-25) with a 3 foot (914 mm) sound attenuator at the end. Return Air Duct Attenuation. Use the Unico Return Air Duct (UPC 4, 5, or 91), duct-board, or sheet metal with acoustical duct liner. Never use flex duct with a solid plastic liner in place of UPC 4, 5, or 91. Isolation. Isolate the air handler with foam rubber strips under the unit. Either hang the unit from the structure using angle iron framework under unit (do not hang directly with hooks in the cabinet) or set on a platform. Piping Secondary Drain Pan. Always use a secondary drain pan wherever overflow of condensate can cause water damage. Do not trap secondary drain line or connect to primary drainpipe. Place secondary drain line exit so that it is apparent when being used. For example, pipe the drain line so it drips on an outdoor windowsill and causes splashing to be noticed. Primary Drain. Always trap primary drain line and run drain line per local plumbing codes. Refrigerant Lines. Follow outdoor section manufacturer's instructions for running refrigerant lines. Size and trap per their instructions. Check Total System Airflow. Check the airflow at each outlet with a Turbometer centered over the outlet. Add up the cfm for all outlets it should not differ by +/- 5% from the design airflow. Startup - DO THIS BEFORE BOXING-IN THE DUCT WORK. Check Static Pressure (optional). Measure the external static pressure in plenum 2 feet (610 mm) from unit and before any fitting. Set as close as possible to 1.5 inches of water (0.37 kpa) or less, but no less than 1.0 IWC (0.25 kpa) or greater than 1.8 IWC (0.48 kpa), by providing adequate number of full outlets and minimum plenum fittings (full flow). Check Amperage. Measure the amperage and voltage of the motor. Verify that it matches within +/- 5% of the values for the desired (design) cfm in the installation manual or the motor amperage table shipped with each air handler. Also, use a Turbometer to measure airflow from each outlet. If the total airflow measured by the Turbometer at the outlets is significantly less than airflow determined by motor amperage, check for system air leaks. Check for Full Flow. Inspect each outlet for full flow (except where orificed); it should be approx. 40 CFM (19 L/s) per outlet. Investigate for blockage or kinks if flow is insufficient. Check Refrigerant Charge. Charge unit per outdoor manufacturer's instructions and Unico's Installation instructions. For best results use the subcooling method during the cooling cycle. Heat pumps should be checked in both heating and cooling. TurboMeter is a registered trademark of Davis Instruments

101 Bulletin / February 2001 OUTLET CAPACITIES 10% RULE (10% reduction for every 5 ft over 10 ft.) (10% reduction for every 1.5 meter over 3 meters) Length, Air Flow, Equivalent ft CFM Full Outlet Length, Air Flow, Equivalent m L/s Full Outlet NOTE: The more supply tubing you use per outlet, the lower your airflow. Make sure to account for long supply tube runs when you design your systems. Copyright 2001 Unico, Inc.

102 EQUIVALENT PLENUM SIZE 7 ROUND = 6.5X6.5 OR 6X8 4X12 3.5X14 9 ROUND = 8.5X8.5 OR 8X10 6X12 4X20 3.5X24

103 EQUIVALENT PLENUM SIZE 10 ROUND = 9.5X9.5 OR 8X12 6X14 4X24

104 RULE # 1 PLENUM LENGTH MAKE MORE MONEY IT IS BETTER TO RUN ADDITIONAL PLENUM IT IS BETTER TO RUN MORE PLENUM

105 RULE #2 60/40 RULE OUTLETS 5 OUTLETS 4 7

106 RULE #3 70/30 RULE

107 RULE #4 HORSESHOE PATTERN BEST PATTERN BECAUSE YOU MAY REDUCE AND BALANCE THE SYSTEM 9 7 7

108 RULE #5 SHOTGUN PATTERN ON A SHOTGUN PATTERN YOU MAY REDUCE AFTER 40% OF THE TAKE-OFFS 40% 60% 10 9

109 24 INCHES RULE #6 24 INCH RULE

110 RULE #7 SPACE TAKE OFFS EVEN 6 BETWEEN TAKE OFFS 12 FROM END CAP

111 RULE #1 PLENUM LENGTH PLENUM S CAN BE UP TO 15O EVERY FITTING HAS AN EQUIVALENCY 1 st TEE = 30 = TO 15 =TO 30 EVERY OTHER FITTING IS = TO 15 = TO 15

112 RULE # 2 THE 10% RULE A RULE OF THUMB ASSUME THAT YOU LOSE 1 CFM FOR EVERY 1 OVER 10

113 RULE # 3 WHERE CAN YOU PUT AN OUTLET? THINK: Q: WHERE CAN T I PUT ONE? A: WHERE IT WILL NOT BLOW DIRECTLY ON SOMEONE OR SOMETHING THAT WILL MOVE EVERYWHERE ELSE IS FAIR GAME CEILING, SIDE WALL, FLOOR

114 RULE # 1 HOW MANY OUTLETS IN A ROOM? 6000 BTUH S / 2000 BTUH S ( F R O ) = 3 OUTLETS 33 CFM ( F R O ) * 3 OUTLETS = 99 TOTAL CFM REQUIRED

115 Bulletin / December 2003 Installation Manual for Air Distribution Systems NOTICE TO INSTALLER AND EQUIPMENT OWNER: RETAIN THIS MANUAL AT THE JOB General The following information is to help the installer save time, provide the best possible installation, and ensure continuous trouble-free operation. All Unico System components are factory fabricated up to the point where they can be assembled on the job as described in this manual. Scope These installation instructions cover the Unico System air distribution system including the return air components and secondary drain pans as shown in Figure 1. This manual describes only the installation of the duct components. Details for wiring, piping, refrigerant line connections and condensate drains are covered in the installation instructions for the specific models and accessories. Specific design procedures are detailed in Bulletin 40-30: Component Layout and Bulletin 40-40: System Sizing and Layout Procedure. Although this manual will occasionally repeat important information, refer to the design bulletins for more detailed information on duct sizing and location. General Precautions and Safety Tips Do not attempt to install or start up the system without first reading and understanding this manual and the appropriate manual for the air-handling unit. Before operation, be sure the unit is properly grounded. The installation should be in accordance with all local codes and regulations and with the National Fire Protection TABLE OF CONTENTS SCOPE... 1 SAFETY TIPS... 1 TOOLS REQUIRED... 1 DESCRIPTION OF SYSTEM... 2 INSTALLATION... 3 Preparation of Work Area... 4 Return Air Opening... 4 Supply Ducts... 4 Outlet Terminator... 5 Mounting the Air Handler... 6 Supply Plenum Connection... 7 Plenum Design... 7 Plenum Installation... 7 Plenum Takeoffs... 9 Balancing Orifices... 9 LEAKAGE REDUCTION... 9 DUCT IN UNCONDITIONED SPACE... 9 WINTER SHUT-OFF Association (NFPA), International Residential Code (IRC), International Mechanical Code (IMC), and Underwriters Laboratories (UL) 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 (NEC) and all local codes and regulations. Condensate piping should be installed in accordance with governing codes. Always install a secondary drain pan when an overflow of condensate could cause damage. Tools Required The following list covers the basic tools required to properly install the Unico System duct components. The list does not include commonly available items such as sheet metal screws, hammers, screwdrivers, etc. 1. Reciprocating saw (e.g. Sawzall * brand or equal) with blades to cut joist, studs and drywall inch (102 mm) carbide tip rotary hole saw for plaster/lathe /2-inch (90 mm) hole saw or wood chipper type blade for hardwood floors. 4. Half of a basketball to fit on hole saw to catch debris. 5. UPC-57 Clamp pliers for duct clamps 6. Amp meter with low scale (less than 10 amps) 7. Turbometer ** air velocity meter. 8. UL-181A-P pressure sensitive foil tape or UL-181B-FX flexible duct tape. Additional materials for fiberglass plenum: 1. UPC-55 2-inch (51 mm) hole cutter ( cookie cutter ) 2. UL-181A-H heat sealed aluminum foil tape or UL-181A-P pressure sensitive foil tape 3. Iron for heat sealable tape Additional materials for metal plenum: /8-inch (48 mm) metal hole saw, or 2-inch (51 mm) as alternative. 2. Tin snips 3. UL-181A-M duct mastic or UL-181A-P pressure sensitive foil tape. * Sawzall is a registered trademark of the Milwaukee Electric Tool Corp. ** Turbometer is a registered trademark of Davis Instruments Copyright 2003 Unico, Inc.

116 Bulletin Page 2 Description of Air Distribution System General. Most Unico Systems are installed in attic or overhead installations. However, give consideration to basement or other suitable conditioned space locations, especially since the Unico System air handlers can be installed in vertical as well as horizontal configurations. These instructions are primarily oriented to the attic type of installation (as shown in Figure 1) but, where appropriate, reference will be made to other possibilities. Note: Where possible the air handler and air distribution system should be located in the conditioned space to reduce energy losses that result in non-conditioned areas, such as attics, garages or unheated utility rooms. Supply Air System. All supply air is distributed through a compact duct system consisting of a plenum and small branch ducts. In some cases, the branch ducts may be omitted. The plenum can be any material provided it is insulated and designed for up to 3 inches of water column (744 Pa) and 2800 ft/min (14.2 m/s). Table 1 lists some common sizes along with the maximum recommended airflow. For applications without branch ducts, the plenum must have acoustical dampening properties. Examples of this are ducts made from fiberglass insulation such as ductboard or Table 1. Equivalent Duct Size, inch (mm) Round Size 7.0 (178) 9.0 (229) 10.0 (254) 11.0 (279) Rectangular Equivalent 6-1/2 x 6-1/2 (165 x 165) 6 x 8 (152 x 203) 4 x 12 (102 x 305) 3-1/2 x 14 (89 x 356) 8-1/2 x 8-1/2 (216 x 216) 8 x 10 (203 x 254) 6 x 12 (152 x 305) 4 x 20 (102 x 508) 3-1/2 x 24 (89 x 610) 9-1/2 x 9-1/2 (240 x 240) 8 x 12 (228 x 305) 6 x 14 (152 x 356) 4 x 24 (102 x 610) 10-1/2 x 10-1/2 (267 x 267) 10 x 12 (254 x 305) 8 x 14 (203 x 356) 6 x 18 (152 x 457) Maximum Airflow 600 CFM (330 L/s) 1000 CFM (472 L/s) 1250 CFM (590 L/s) 1500 CFM (708 L/s) metal ducts with internal fiberglass insulation lining. All branch runs are 2-inch (51 mm) in diameter. Unico has two types of branch ducts: UPC-26C Sound Attenuator and UPC-25 aluminum core tubing. All branch ducts must include at least 3 feet (1 m) of sound attenuator to maintain proper sound levels. For maximum sound attenuation, the entire duct run can be made from the sound attenuator. The Supply Outlet Sound Attenuator Take-Off 2" Supply Tubing Coupling Sound Plenum Attenuator Elbow, 90 Plenum Duct Full Flow Tee Restrictor (incl. w/ blower) Modular Fancoils M2430/3642/4860 Blower Module Cooling Module Heating Module Plenum End Cap Turning Vane (for Tee) Supply Adapter Secondary Drain Pan Supply Adapter One-piece Fancoil M1218 Secondary Drain Pan Figure 1. Air Distribution System components (fiberglass plenum shown) Return Air Adapter (Heating) Return Air Duct Return Air Adapter (Heating and Cooling) Return Air Adapter (Cooling) Return Air Box IL00343a.CNV Copyright 2003 Unico, Inc.

117 Bulletin Page 3 ducts are available with four different insulation thicknesses to achieve higher R-factor ratings: R3.2 (STD), R- 4.2, R-6, and R-8. The entire branch duct can be made of the sound attenuator (method A, Figure 2) or with 3 feet (1 m) of sound attenuator and the rest made of aluminum supply tubing (method B, Figure 2). For branch runs over 12-feet (3.6 m) long, method B recommend because the aluminum duct is stronger than the sound attenuator and long runs usually are handled more roughly. Note: For proper acoustical attenuation, always use at least 3 ft (1 m) of sound attenuator supply tubing at the end of each run. Supply Outlet (UPC-56B, UPC-57, or UPC-58-1-XX) Scrim Core Clamp (UPC-53) Supply Outlet 3 ft. min Sound Attenuator Supply Tubing Alum. Core Clamp (UPC-52) Scrim Core Clamp (UPC-53) Sound Attenuator Supply Tubing (12 ft. Max.) (UPC-26C) Method A (for 6 to 12 ft. runs) Aluminum Core Supply Tubing (UPC-25) Supply Tubing Coupling (UPC-38C) Method B (for 6 to 50 ft. runs) Figure 2. Branch duct assembly Scrim Core Clamp (UPC-53) Takeoff (UPC-23B or UPC-28) Takeoff IL00111a.CVS The branch ducts terminate with either a round or rectangular outlet. The outlets come in a variety of colors and finishes, including several species of wood, unfinished. The round outlets are usually the best choice for floor or ceiling outlets. The rectangular outlets are ideal for outlets in a wall and are designed for standard 2 x 4 construction. The rectangular or slot outlets are available in both cast aluminum and plastic. In addition Unico has an angled round outlet designed for sloped ceilings. For applications without branch ducts use the plenum slot outlets, part number UPC-101. For certain applications where it is desired to attach the outlet as close as possible to the plenum, a 12-inch (31 cm) rigid sound attenuator is available. These attenuators are available in kits. Use kit UPC-84-5 for fiberglass plenum and kit UPC-85-5 for sheet metal plenum. The kits include all the necessary components to complete an outlet branch run. These kits are well suited for masonry or concrete structures with no ceiling joists or crawl spaces. They can also be used for under-slab installations. See Bulletin 20-60: Rigid Sound Attenuator for installation details. For exposed duct applications, use the UPC-101 slot outlet attached directly to the plenum. This is acceptable as long as 7 outlets per nominal ton (2 outlets per nominal kw) are used and the plenum is acoustically lined or made of fiberglass ductboard. Return Air System. Unico supplies factory made components for the complete return air system that includes the return air box with grille and filter, return air duct and return air adapter. These components are ideal for horizontal attic type installations where one central ceiling return can be used. Where the single packaged return air system can not be used, such as in tight closets, vertical installations or where multiple returns are needed, a field fabricated return duct system made from ductboard, or sheet metal with acoustical lining can be used. A 90 bend or elbow should be used in the field fabricated return system for proper acoustical performance. Each Unico System air handler is designed with a rectangular return air opening that will accommodate the field fabricated duct which should be designed for a pressure loss not to exceed.15 inches of water column (IWC) (37 Pa), including filter. Generally, this means sizing the duct for a pressure loss of.05 IWC at the required airflow and sizing the filter for a pressure drop of.10 IWC at the required airflow. It may help to remember that the return duct system is a conventional design, not high velocity. Note: For more detailed information on return duct design see Tech Note 106, Return Duct System Design Requirements. General Installation Procedure The following procedure is a general guideline describing the most popular installation sequence. It is not required to proceed in the same order; however, each step must still be done. 1. Produce sketch of duct design showing approximate location of all outlets, the air handler, the return openings, and a layout of the supply plenum and return duct. 2. Locate and cut the openings for the outlets and the return air openings. 3. Install the branch ducts. 4. Install the outlets and mount to floor or ceiling. 5. Mount the air handler 6. Install plenum 7. Connect branch ducts to plenum 8. Install return grille and return duct 9. Connect electrical power 10. Test airflow 11. Connect refrigerant lines and charge 12. Fill out service report form for records Copyright 2003 Unico, Inc.

118 Bulletin Page 4 Preparation of Work Area It is recommended that good lighting and a fan be provided when working in poorly ventilated attic or crawl areas. The fan can be set over the return air opening and used to force cooler air into the area during installation. Another useful tip is to run a sprinkler on the roof during installation to keep the attic temperature down. For attic and crawl space installations many installers find it practical and easier to use working boards laid over the open joists or on the ground. These are 16-inch (41 cm) wide plywood sheets 8-foot (2.4 m) long. They are saved and carried from job to job. Return Air Opening Cut the opening for the return air box in accordance with the dimensions of Table 2. By doing this first it provides an opening to move equipment and components into the attic when other access is not sufficient. Table 2. Return Air Box Opening Return Air Box Models Part No. Size of opening inches (mm) 1218 UPC x 20½ (365 x 520) 2430 UPC ½ ( ) 3642 UPC ( ) 4860 UPC ( ) If the joists or studs are less than 16 inches (41 cm) centerto-center or in the wrong direction, it will be necessary to cut and header the joists or build a frame to hold the return air box. 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 box inside the surrounding frame using nails or screws. Holes are provided in the long sides of the return air box. Use the four (4) ¼-inch (6.4 mm) holes nearest to the corners. The other holes are for mounting the filter grille (Figure 3). Install filter frame into the return air box using four (4) nails or screws. Use the holes furthest from the corners. Insert filter and hold in place by rotating metal clips. Close FRAMING 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 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-P aluminum tape. Supply Outlet and Branch Run Installation Parts Required. Each branch run is made entirely of sound attenuator duct or sometimes connected to an aluminum duct. All the items necessary for branch construction, including plenum connections and terminations, are listed in Table 3. Table 3. Branch Run Parts Part No. Description Sound Attenuator Tubing, (5) 12 ft (3.6 m) UPC-26Cxx-5 lengths (xx - indicates optional R-factors, R4/R6/R8) Aluminum core Supply Tubing, (4) 25 ft (7.3 UPC-25xx-4 m) lengths (xx indicates optional R-factor, R4/R6/R8) Installation Kit (for fiberglass plenum), 5 outlets, includes takeoffs, clamps and couplings UPC-89F-5A Installation Kit (for metal plenum), 5 outlets, UPC-89M-5A includes takeoffs, clamps and couplings Outlet Kit (for fiberglass plenum), single outlet with 12 ft (3.6 m) sound attenuator UPC-80F-1 Outlet Kit (for metal plenum), single outlet UPC-80M-1 with 12 ft (3.6 m) sound attenuator UL181A-P Aluminum Tape All the necessary items to make a 12-foot (3.6 m) branch run from the plenum to the supply outlet are available in the single outlet kits. For lengths grater than 12-foot (3.6 m), the 2-inch (51 mm) aluminum supply tubing must be ordered separately. The materials are also available in bulk packaging with the outlets and hardware sold as a 5 outlet Installation Kit and the sound attenuator sold separately. Outlet types. There are several types of supply outlets, each of which was designed for a specific application although all of them can be used for various applications. The standard outlets are white plastic which can be painted to match the wall and are also available with a metallic finish. Outlets are also available with a wood faceplate made of unfinished oak as standard or other wood species as a special. Consult Unico for availability of colors, finishes, and wood species. FILTER Figure 3. Return Air Box and Filter Grille Copyright 2003 Unico, Inc. RETURN AIR BOX FILTER FRAME FILTER GRILLE IL00048.CNV The basic round outlets are designed for ceiling and floor applications although it is not unusual to place them in the side wall. The sloped outlets are a variation of the round outlets and are designed for sloped ceiling applications. The round outlets with wood faceplates are designed primarily for floor applications and come standard with a screen. The slotted outlets are designed for side wall applications or low clearance dropped ceilings. Their advantage is that they are available with a 90 elbow to facilitate installation in tight spaces.

119 Bulletin Page 5 Installation of Supply Runs. Supply outlet locations should be pre-determined in accordance with the prepared layout following Bulletin 40-30: Component Layout. The outlets can be placed in the ceiling, floor or wall. The best place for ceiling outlets is the corner center of hole 5 inches (125 mm) from each wall, or 3 inches (75 mm) from each wall if using the slotted outlet (Figure 4). If that is not possible or practical, anywhere out of the traffic pattern is acceptable. 4 (100) 5 (125) 5 (125) 3 (75) For round floor outlets, be sure an outlet screen (UPC-88) is installed to prevent objects from falling into the duct. This screen is included with the UPC-57 unfinished wood outlet. WARNING: ADVISE THE HOMEOWNER THAT THE SCREEN IS NOT DESIGNED TO HOLD WEIGHT. TO PREVENT POSSIBLE INJURY DO NOT STEP ON SCREEN. For side wall outlets, position the outlet above head height as near to the ceiling as possible. The standard round supply outlet can not be installed in a stud wall as there is insufficient room to bend the sound attenuating tubing. For such installations use the slotted outlet. Otherwise, if there is room for a bend radius 6 inches (152 mm) or greater, such as a soffit above a kitchen cabinet or space above closet doors, it is acceptable to use a round terminator. After the approximate location of the outlet is determined a hole must be cut and the supply tubing routed to the outlet location. Follow these steps when installing the supply tubing: 1. Make branch runs at least 6 feet (1.8 m) to prevent noise from excessive air flow. The entire branch duct can be sound attenuator or it can be a combination of sound attenuator coupled to the aluminum supply tubing. In either case, each branch duct must have at least 3 feet (1 m) of sound attenuator at the end. 2. Use as few bends as possible. 3 (75) Figure 4. Location of corner outlets 1.0 x 9.25 (25 x 235) 3. If bends are necessary, provide as generous a bend radius as possible. The minimum radius is 6-inches (152 mm). 4. Support the supply tubing every 4 feet (1.2 m). 5. Be careful not to tear or puncture the supply tubing outer jacket. For New construction Applications (round outlets): 1. Install a plaster frame kit (UPC-86) where the outlet will be located. See Bulletin 20-80, Plaster Frame Kit. 2. Route the supply tubing so about 6 inches (152 mm) of the attenuator protrudes through the hole in the plaster frame. IL00348.CNV 3. If you have access to the plenum after terminator is secured, do this step last. Be sure there is sufficient tubing to provide as generous a radius (6-inch minimum) as possible at the outlet. Remove the excess supply tubing at the plenum and connect to the plenum takeoff. 4. Push the duct up into the hole and install the drywall or paneling, cutting the appropriate 4-1/4-inch (108 mm) hole for the frame. 5. Pull the duct out and attach the duct core to the outlet terminator. Be sure to cut off any excess core. DO NOT ALLOW THE CORE OF THE DUCT TO BUNCH UP AND DO NOT CREATE A SHARP BEND NEAR THE OUTLET THIS CAN CREATE NOISE. 6. Position the terminator in the hole and secure with toggles and screws. For New construction Applications (slotted outlets): 1. Install the outlet inside the wall cavity using the mounting bracket and hanger bars. See Bulletin 20-70, Slotted Outlet Specifications. 2. Route the sound attenuator from the outlet to the plenum. 3. Connect the sound attenuator to outlet and takeoff with the clamps and then seal the vapor barrier with aluminum foil tape. 4. Install the gypsum board and finish the interior wall. Then attach the trim plate. For Existing Structures (round outlets): 1. Cut a 4-inch (102 mm) hole in the plaster or drywall. To be sure there is adequate clearance around the outlet location so the 4-inch (102 mm) hole can be cut without running into any obstructions, first drill a small (1/8-inch (3 mm)) hole at the outlet location and check above the ceiling or below the floor to see that there is 2-inch (51 mm) clearance all around the hole. After assuring adequate clearance, cut the 4-inch (102 mm) hole with a rotary hole saw using the small hole as a pilot hole. 2. Then either route the supply duct through the hole to the plenum or from the plenum to the hole. If it is necessary to pull the duct through a floor joist, use either an electrician s fish tape or rope. 3. Remove any excess supply tubing at the plenum and connect to the plenum takeoff. 4. Allow about 6 inches (152 mm) to protrude through the hole, removing any excess and connect to the outlet terminator. Remember that as generous a radius as possible is desired at the outlet for good acoustical performance. Connecting Duct to takeoff, coupling or outlet. Follow these steps to connect the duct to a takeoff, coupling or outlet: 1. Pull back the jacket and insulation about 2 inches (51 mm) to expose the inner core. 2. Slip the core over the connection stub of the takeoff, coupling or outlet as far as you can. Then secure with clamp using clamp pliers (UPC-54). Use the UPC-53B clamp for clamping the sound attenuator core and the UPC-52 clamp for clamping the aluminum core. 3. Stretch the insulation and outer jacket over the core and stub and stuff under the tape ring. Secure the outer jacket with UL181A-P aluminum tape. Copyright 2003 Unico, Inc.

120 Bulletin Page 6 Duct Penetration between Floors Whenever you penetrate a floor with the ducts, special care must be taken to assure that the installation is in compliance with the building codes. There are several different methods of installation, depending on the application. Outlet Terminator Installation With the outlet terminator connected to the end of the sound attenuator install the two toggles and screws in the mounting holes in the terminator faceplate. Feed or pull the terminator through the 4-inch (102 mm) hole in the ceiling or floor until the two spring toggles begin to enter the hole. Force the upper portion of the toggles inward until they snap over the edge of the ceiling or floor. The toggles should be centered on a line parallel to the direction of the duct run from the outlet to the plenum takeoff. Loosen the screws if necessary to assure toggles are sprung over the edge of the hole. Tighten the screws until the cover plate is snug against the ceiling or floor. CAUTION: TO PREVENT DAMAGE TO THE OUTLETS DO NOT OVERTIGHTEN THE TOGGLE SCREWS. The supply outlet can be installed in the floor without toggles by drilling a hole 3-3/8-inch (86 mm) in diameter instead of 4-inch (102 mm) and screw the cover plate directly to the floor by drilling two 5/64-inch (2 mm) diameter holes on a 3-3/4-inch (95 mm) diameter bolt circle. The UPC-56B supply outlet can be inserted into the 3-3/8-inch (86 mm) hole and used as a template for the two screw holes. When installing the screws be careful that they do not break into the 3-3/8-inch (86 mm) hole; drill and install at a very slight angle away from the 3-3/8-inch hole if necessary. Connecting Outlet to R-6 and R-8 duct. The R-6 and R-8 ducts require special installation instructions because the duct is too large to pass through a 4-inch (102 mm) hole. To properly install these outlets you will need access to both sides of the wall. These ducts have two layers of insulation and two vapor barriers. Simply peel back the outermost vapor barrier and layer of insulation, exposing the inner vapor barrier. The inner layer is the same thickness as the R-4.2 and will pass through the 4-inch hole. Then clamp the inner duct and seal it the same as any standard or R-4.2 duct. Push the outlet into place and secure it to the ceiling or wall with the toggles. From the backside of the wall unroll or unpeel the outer insulation and vapor barrier to its previous position. Then tape any seams with UL-181A-P tape. If you do not have easy access to backside of the wall, then you will need to attach a short length of standard sound attenuator to the R-6 or R-8 duct. Use a 3-foot (1 m) section of sound attenuator coupled to the inside vapor barrier of the heavier insulated duct. Push the outer insulation away from the outer vapor barrier and then seal the outer vapor barrier to the tape ring of the coupling with aluminum tape. UPC-57 Unfinished Wood Outlet Installation. Cut a 3-3/8-inch (86 mm) hole for mounting the UPC-57 without using toggles. The UPC-57 is furnished without any mounting holes in the wood faceplate. Rather than mar the wood surface an adhesive can be used under the faceplate to adhere it to the floor or other mounting surface. In some cases for floor applications the weight of the tubing below the floor will keep the outlet in place without any retention means. If desired, holes can be drilled in the wood face plate at about a 3-7/8-inch (98 mm) bolt circle and wood screws used to mount the UPC-57 directly to any wooden mounting surface, such as the floor or paneling on the wall or ceiling. Mounting the Air Handler The Unico System air handlers can be either platform mounted or suspended from the ceiling or attic rafters as detailed in Bulletin 30-20: Modular Unit Installation Instructions. The M1218 can be mounted flush to the ceiling or vertically against a wall using the mounting rails. Secondary Drain Pan. Where an overflow of condensate could cause water damage, a secondary drain pan MUST BE INSTALLED. Table 4 lists the models and dimensions of the secondary drain pans for horizontal installations. For vertical installations a secondary drain pan should be fabricated so the dimensions are about 2 inches (51 mm) greater than the footprint of the base of the air handler. Place the drain pan on the mounting base, platform or angle iron frame. Be sure to allow enough room for the drain line connection. The assembled unit should be placed over the secondary drain pan supported by rails with rubber pads for isolation to raise the unit above the 1.5-inch (38 mm) sides of the secondary drain pan. Like the modules, all secondary drain pans except UPC- 24C and 24D will fit through the return air opening. Those drain pans may simply be folded and unfolded to fit through the return opening. Table 4. Secondary Drain Pan Dimensions, inches (mm) Model Part No. Size 1218 UPC x 22 (1016 x 559) Model 2 Modules 3 Modules Part No. Size Part No. Size 2430 UPC 20B 3642 UPC 24B 4860 UPC-24C ( ) ( ) ( ) UPC 20C UPC 24C UPC-24D ( ) ( ) 40 x 54 (1016 x 1372) NOTE The drain fitting extends 7/8 inch (22 mm) beyond this dimension. Copyright 2003 Unico, Inc.

121 Bulletin Page 7 Plenum Connection to Air Handler Install Plenum Adapter. Use the UPC-61 supply plenum adapter for round metal plenum (Figures 5 and 6). Use the UPC-62 supply adapter for square fiberglass ductboard plenum (Figure 7). Any other shapes or sizes require a field installed adapter. First install the restrictor plate on the blower (Models M2430, M3642, and M4860 only). Position the restrictor in the full open position with the screws tight but still able to move the restrictor. Blower Module Restrictor Plate Plenum Adapter Blower Cabinet Fiberglass Plenum Figure 6. Square plenum adapter installation. Insulation Tape IL00049a.CVS Plenum Insulation Wrap Plenum Adapter Figure 5. M1218 Plenum Adapter Installation Blower Module Restrictor Plate Plenum Plenum Adapter IL00155.CV5 Restrictor Setting Scale Insulation Wrap Figure 7. M2430/M3642/M4860 Round Plenum Adapter Installation Connecting Metal Plenum to Plenum Adapter. To connect a metal plenum, slip the un-crimped end of the plenum duct over the crimped end of the adapter. Secure the duct with a minimum of three self-tapping sheet metal screws at the joint and seal all seams with UL-181A-P pressure sensitive tape or UL-181A-M duct mastic. Then wrap the 1-inch (25 mm) thick fiberglass blanket insulation around the UPC-61 adapter and seal again with UL181A-P tape. Make the blanket snug but not compressed to maximize the insulation effect. Connecting Fiberglass Plenum to Plenum Adapter. Cut off the male ship-lap to make the end flush; then insert the duct into the plenum adapter. Push plenum in tightly to form a snug joint. Insert four large headed nails at least 1- inch (25 mm) long through the four holes on each side of the square plenum adapter to help secure the duct. Then seal the duct to the metal collar with UL-181A-P tape. Be sure to use a squeegee to adhere the tape. After the duct is sealed to the adapter, wrap the supplied insulation tape around the exposed metal of the adapter to prevent condensation. Plenum Design As described in Bulletin 40-30, the best plenum design is the perimeter loop because it uses a tee to split the flow. This effectively reduces the pressure drop of the entire duct system and also boosts the plenum static pressure. For best performance, the tee should be the first fitting coming off the air handler at least 4 feet (1.2 m) away, but no closer than 24 inches (61 cm). The plenum size, using internal dimensions, should be based on the maximum airflow shown in Table 1. For simplicity and to take maximum advantage of static regain, do not downsize the plenum except where needed for tight spaces. In some cases, when the plenum equivalent length is over 150 feet (45 m), the plenum should be oversized. For example, the M2430 with 550 CFM (259 L/s) will use a 7-inch (18 cm) ID plenum per Table 1. However, if the equivalent plenum length is over 150 feet (45 m), it should be upsized to 9-inch (23 cm) ID. Plenum Installation Fiberglass Plenum. Before beginning plenum installation it will save on fabrication of plenum joints if the layout is consulted as to the location of tees and elbows in relation to the air handler. Proper planning at the outset as to the match-up of these joints can save on having to fabricate ship-lap joints when the standard 4-foot plenum lengths are cut to shorter lengths. Copyright 2003 Unico, Inc.

122 Bulletin Page 8 Where fiberglass is used, the plenum, tees, and elbows are supplied with pre-fabricated male and female ship-lap * joints on each end. Tees and elbows are supplied with male and female ends as shown in Figure 8. Once the duct sections are fitted together, use either UL- 181A-H heat seal tape (UL-181A-P pressure sensitive tape or UL-181A-M duct mastic may also be used) to connect the sections together. The UL-181A-H is a heat seal tape that requires the use of a hot iron. Done properly, it is the most secure joining method. However, it is difficult sometimes to maneuver the iron when you are in tight spaces. Therefore, as alternative, use the UL-181A-P tape or UL- 181A-M duct mastic to join the sections. Be sure to use a small squeegee to apply pressure to the tape. And always be sure that external surface of the duct is clean. For more information, refer to the manufacturer of tape, regarding shelf life, surface preparation and application temperatures for these closure systems. Continue to assemble plenum making sure ship-lap joints are snug. Tape each joint securely with UL181A-H heat activated tape (available as UPC-17). For square plenum use a short 4-inch (102 mm) piece of tape on each side of the ship-lap joint taping across the flap. Be sure to pull flap tight before ironing. Once all four sides are secured, tape completely around the duct. As each length of plenum is added be sure it is properly supported so no strain is put on the joints. The square tees and elbows have tape flaps on all four sides of each male ship-lap joint. The end cap has extra foil facing that extends on each side to serve as a tape flap. To facilitate folding the flap over each side of the plenum the end cap flap can be cut at each corner. Be sure tape is centered over the joint and provide an overlap of at least 2 inches (51 mm) at the end of the tape before ironing. Be sure surface of plenum is clean and free of dust or dirt. Metal Plenum. All joints, including the longitudinal snaplock seam in the metal pipe and the tee and elbow joints must be sealed with UL181A-P tape to prevent any air leakage. The complete metal plenum system should be insulated with a minimum of 1.5 inches (38 mm) of fiber- * Female Male Figure 8. Tee and Elbow End Configurations The pre-fabricated male and female ends on the plenum and plenum fittings are most commonly called ship-lap joints. Tools are available to facilitate fabrication of the male and female ship-lap joints on the ends of the plenum. Alternatively, a utility knife can be used to form ends. Ends properly cut should fit snugly. glass insulation with vapor barrier. Where higher R factors are desired, the thickness of the insulation can be increased. Insert male crimped ends into the un-crimped female end. Use a minimum of three self-tapping sheet metal screws to mechanically secure each plenum joint, including the one at the plenum adapter. Tape each joint using UL-181A-P pressure sensitive tape or use UL-181A-M duct mastic. Be sure that all longitudinal seams of the metal pipe are also sealed with tape. It is also helpful to locate the longitudinal seam at one location such as at the top of the pipe as once the pipe is insulated the longitudinal seam is to be avoided for cutting holes for the attachment of the plenum takeoffs. Insulate the bare metal with a minimum of 1-1/2 inches (38 mm) of fiberglass insulation with vapor barrier and tape securely in place. Use either an aluminum foil faced fiberglass insulation blanket or a silver insulation sleeve. Tape all insulation seams with UL-181A-P or UL-181B-FX tape. Be careful not to compress the insulation while wrapping it around the duct or while taping the seams. When using metal plenum, be sure that the elbows have a generous radius and the tees are the full flow design. All joints in tees and elbows must be sealed with UL181A-P tape before insulating. Never use an elbow as the first fitting off the air handler; always use a least 24 inches (61 cm) of straight duct before the elbow and use large radius elbow. If a tee is not used, maintain the maximum duct size whenever possible. Reduce the duct size only if the plenum equivalent length is less than 150 feet (46 m) and the airflow is below the maximum allowable in Table 1. Accidental punctures or tears in the plenum facing should be repaired to minimize leakage and provide a neat appearance. If the damaged area is small repair it with the same tape as used for sealing the plenum joints or vapor barrier. Where large areas of the facing have been damaged in fiberglass duct remove the section of damaged duct and replace with new duct, using ship-lap joints at both ends. Plenum Support. The plenum can be extended horizontally and rest directly on floor or ceiling joists or be suspended from above. When hanging fiberglass plenum, be sure the hanger will not damage the plenum facing. Use either plastic or metal strapping material with minimum width of 1-inch (25 mm) (see Figure 9). Covering the metal hanger with a cloth type duct tape will help to avoid the puncturing the facing. Hangers should be no greater than 6 feet (1.83 m) apart and located as close to plenum joints as practical. When hanging or supporting metal plenum, additional steps should be taken over those used with fiberglass plenum to avoid condensation at the points of support since the fiberglass surrounding the metal plenum will compress and significantly reduce the R-factor. At these points a saddle of rigid fiberglass or foam rubber should be provided to rest the plenum in. Copyright 2003 Unico, Inc.

123 IL00091.CVS Bulletin Page 9 discs are designed to just press into the orifice cap before installing over the connector stub protruding from the plenum takeoff fitting. The cap is designed to fit snugly over the connector stub and still permit the 2-inch (51 mm) ID insulated supply tubing core (UPC-25 or UPC-26) to slide freely over it. 1" (min.) 24 gauge 1" (min.) 24 gauge 1" (min.) 24 gauge il00199.cnv Table 5. Outlet-Orifice Combination Desired Number of Outlet-Orifice Combination Outlets*.5 (1).5.65 (1) (1) (1) 1.15 (1).5 + (1) (2) (1).35 + (1).15 or (1) + (1).5 or (3) (1) + (1).35 or (2).5 + (1) (2) (2).35 + (1) (1) + (1) (3) (2) * For a room requiring more than 2 outlets use combinations of above table quantities. Figure 9. Hanging Fiberglass Plenum Plenum Takeoff Installation Figure 10. Plenum Takeoff Location 15 Refer to Bulletin 30-50: Plenum Take-off Installation Instructions for complete details for attaching the take-offs to the plenum (Figure 10). Balancing Orifices The Installation Kits (5 outlet) include one of each of the 3 sizes of balancing orifices. The UPC Takeoff balancing Orifice Package is available where additional orifices are needed. They reduce airflow for the individual branch runs to better balance the air supplied to rooms for the cooling and heating loads. Upon completing the individual room heat gain and heat loss calculations and determining the number of outlets, the runs requiring orifices should have been determined allowing for the 3 sizes of orifices which give 15%, 35%, and 50% reduction in air flow. See Table 5 for the combinations that can be used. These orifices are mounted at the UPC-23 or UPC-28 takeoff fittings. The orifice cap alone provides the 15% reduction, the cap with the.266-inch diameter hole disc provides 35% reduction and the cap with the.188-inch diameter hole disc provides 50% reduction in airflow. The IL00096 Reduction of Leakage and Energy Losses For fiberglass plenum systems with all plenum joints taped carefully using the UL181A-H tape, there should not be any leakage from joints or be any need to mechanically brace plenum fittings into which air impacts. This may be necessary when other tapes are used. In such cases, a caulking compound (such as DAP butyl rubber) or fiberglass adhesive should be used at all plenum joints to reduce leakage and energy losses. In unconditioned locations, and especially in more humid areas, it may be necessary to over-wrap the joints with foilfaced fiberglass and tape in place covering all edges to provide a complete vapor barrier. The R-factor of 1 inch (25 mm) thick square fiberglass plenum is 4.2. Where a higher R factor is desired it is usually better to use a metal plenum as it can be over-insulated with thicker insul-sleeve or blanket insulation with thicker insulation. Alternatively, thicker fiberglass ductboard may be used but this complicates the installation because the elbows and tees must be fabricated in the field. Several manufacturers make a 1-1/2-inch (38 mm) ductboard (R-6) (2-inch (50 mm) ductboard is also available in R-8). Special spin-in takeoffs are available for the 1-1/2-inch ductboard. Duct System in Unconditioned Spaces To minimize energy losses it is best to run the duct system in conditioned spaces, such as basements, utility rooms, and closed or furred down areas. When the distribution system is located in unconditioned spaces and especially in the more humid areas of the country, it may be necessary to take extra precautions against condensation as follows: 1. Be sure tape rings are used at every 2-inch (51 mm) tubing connection. They are specifically intended to Copyright 2003 Unico, Inc.

124 Bulletin Page 10 keep the insulation from being compressed whenever a joint is being taped. Since the connection joints are more susceptible to leakage and condensation they can be over-wrapped with a 6-inch (152 mm) wide piece of foam insulation tape or fiberglass insulation with a vapor seal. All edges of the fiberglass overwrap should be taped with UL181A-P tape to assure a complete vapor barrier. 2. At the takeoff fitting (UPC-23 or UPC-28), cuffs of Rubatex type or equivalent tubing 3-1/4 x ¼-inch (82 x 6 mm) or 3/8 x 6-inch (10 x 152 mm) long can be slipped over the supply tubing and pushed snugly against the plenum vapor barrier (Figure 11). A good adhesive, such as DAP butyl caulking compound or equivalent, can be used to seal the end of the Rubatex cuff to the plenum vapor barrier. The other end of the cuff should be sealed to the supply tubing jacket with UL181A-P tape to form a complete vapor barrier. The caulking compound can be used to fill this joint before taping. Figure 11. Extra insulation around takeoff connection. 3. Similar to step two (2), precautions can be taken at the supply outlet (UPC-56B). Use a similar Rubatex cuff and slip this piece over the scrim core tubing where it is connected to the supply outlet. Notch or compress the Rubatex so it slips over the taping collar of the UPC-56B between the collar and toggles so the Rubatex can seat against the back of the supply outlet face plate; adhesive can be used to seal cuff to back of face plate. To facilitate the installation this cuff might be pre-assembled to the supply outlet-scrim core tubing connector assembly taking care that the toggles are free to compress and snap over the ceiling or floor. 4. Plenum joints can be over wrapped with 6-inch (152 mm) wide vapor barrier faced insulation and taped in place covering all edges to provide a complete vapor barrier. 5. In extreme humidity areas the air handler can also be protected against condensation by covering the top, sides and ends with foil-faced duct board. All bare ends and joints should be taped with UL181A-H to give a complete vapor barrier. Since side panels and the control box cover may have to be removed, leave cut outs or taped pieces (use UL181A-P tape) that can be easily removed. 6. A complete distribution system can be supplied that provides an R-factor of 6 or higher using the following: a. Both the Sound Attenuator and the aluminum supply tubing are available with an R-4.2, R-6, and R-8 rating. b. Use metal plenum and over-insulate with insulation sleeve or blanket insulation. Square fiberglass plenum can be made from either 1 inch (25 mm) or 1-1/2-inch (38 mm) ductboard to provide R-6. This complicates making plenum takeoffs and requires special tees, elbows and plenum adapter. c. For additional information refer to Tech Note 102, Duct Condensation. Winter Air Shut-off For cooling only systems where the air distribution system is located in an unconditioned space, such as the attic or an unheated garage or utility room, steps must be taken to keep moisture from collecting in the duct and plenum system during the winter months. Winter supply air shut-off plugs are included in the Installation Kits. They can also be ordered separately in kits of 20 as UPC These plastic plugs fit into the supply outlet opening. Push them in until they seat against the ledge inside the mouth of the supply outlet (see Figure 12). In addition to the winter shutoff caps, be sure to seal the return air opening. Use both plastic sheet and tape to seal the filter in place or wrap the filter with plastic so that no air enters the return. BE SURE THE HOMEOWNER UNDER- STANDS THE WINTER SUPPLY SHUTOFFS AND THE RETURN AIR SHUTOFF PLATE ARE TO BE INSTALLED AT THE BEGIN- NING OF THE HEATING SEASON AND MUST BE REMOVED WHEN THE COOLING SYSTEM IS STARTED IN THE SPRING. Figure 12. Installing winter shutoff caps. IL00351.CNV Copyright 2003 Unico, Inc.

125 Bulletin / April 2005 INSTALLATION INSTRUCTIONS FOR ELECTRIC FURNACES General The information on the following pages is to provide the installer the necessary information to properly install the Unico System electric furnaces. WON Single-Phase, 240V 4-3-Phase, 240V Nominal kw Rating (050=5kW) The electric furnaces are designed to provide primary heating or auxiliary heating in a heat pump system. The model numbers, kw, and Unico System match-ups are shown in the Table 1 below: Table 1. Electric Furnaces Model Number WON0502 WON0504 WON0752 WON0754 WON1002 WON1004 WON1502 WON1504 Nominal kw Rating Unico System Match-up Min. Airflow, CFM (m 3 /s) (0.12) All sizes (0.14) , (0.24) and (0.28) WON and (0.38) The furnaces include the following features: Cabinet enclosure, Galvanized insulated sheet metal Magnetic de-energizing contactors for each element Line level auto limit primary safety 165ºF (74ºC) Line level fuse link back-up safety Fan interlock control, fan signal proving switch Circuit Breakers on all units Time delay sequencers for a gradual power draw (soft start) Low voltage terminal strip (24 volt control) Specially designed tight cabinet 10 [254] END VIEW Specifications TOP VIEW 12 [305] 4 [102] AIRFLOW 12 [305] SIDE VIEW Dimensions in inches [mm] IL00002c.CVX Figure 1. Electric Furnace (10 inch [254 mm] supply duct collar shown) Table 2. Furnace Specifications Model L inch (mm) Rated Capacity 240V WON (330) WON (406) WON (406) WON (533) WON (610) WON (533) WON (533) WON (533) WON (533) All Unico System furnaces include a 10-inch (254-mm) round plenum adapter and 9½ 9½-inch ( mm) square plenum adaptor. Other plenum adapter sizes are available separately. See Table 6 for a list of plenum adaptor part numbers. Copyright 2005 Unico, Inc.

126 Bulletin Page 2 Location and Mounting Before installing the furnace, inspect the unit thoroughly for shipping damages. Notify carrier immediately if there is any damage. Check all porcelain insulators for breakage and inspect furnace element wire to see that none have been deformed. Check the heating elements for loose connections from shipping that could cause overheating. 3. Insert the furnace into the furnace adaptor and install the mounting screws. Adjust the restrictor plate to the proper airflow (refer to Bulletin 30-20) then use sheet metal screws to secure the restrictor plate in place. 4. Use a hanging strap to support the furnace by attaching one side to the top of the air handler and the other to the end of the furnace (see Figure 3). Install the furnace by attaching it directly to the air handler using the adaptor collar and gaskets provided with the furnace. Position the unit so the arrow label on the cover is in the direction of the airflow and the control box is on either side of the unit as shown in Figure 3. Modular Blower Mounting Instructions: (MB2430L, MB3642L, and MB4860L) 1. Attach the 1/4-inch (3.2 mm) gasket to the inlet side of the electric furnace and the 1/8-inch (6.4 mm) gasket to the adaptor collar between the collar and air handler (see Figure 2). Electric Furnace Control Box (Mount on either side) Hanging Strap Furnace Adaptor Restrictor Plate Blower Module 2. Next attach the adaptor collar to the air handler centering the collar horizontally over the blower opening and flush with the bottom of the blower. Use self piercing screws to attach the adaptor collar to the air handler leaving the top clear of mounting screws to slide the restrictor plate in place. Slide the restrictor plate behind the adaptor collar to the full open position (see Figure 2). Blower Module Center collar over blower opening M-Series Blower END VIEW Restrictor Plate No Screws Adaptor Collar Mount flush with bottom of blower Figure 3. Hanging Strap Placement IL00380.CVX Fancoil Mounting Instructions: (M1218) Mounting the electric furnace on the M1218 fancoil utilizes the same furnace adaptor and gaskets without the restrictor plate and hanging strap. Use the existing screws on the M1218 fancoil to mount the furnace adaptor as shown in Figure 4. Then insert the furnace into the furnace adaptor and install the mounting screws. Electric Furnace Mounting Screws Restrictor Plate M1218 END VIEW Furnace Adaptor Kit Furnace Adaptor Kit M1218 Electric Furnace Blower Module IL00385.CVX Electric Furnace Gasket Dimensions in inches [mm] Gasket Figure 2. Furnace Installation IL00386.CVX Figure 4. M1218 Electric Furnace Mounting Copyright 2005 Unico, Inc.

127 Bulletin Page 3 All furnaces are suitable for zero clearance between duct and combustible material. For servicing the control box, allow enough room to swing open the cover. It is hinged on the downstream end of the panel and latched on the other end. For horizontal applications, mount the furnace with the control box on either side as shown in Figure 3, not on top or bottom. For vertical installations, the control box may be mounted in any position. CAUTION DO NOT HANG UNIT DIRECTLY FROM HOUSING TO PREVENT DAMAGE TO THE ELECTRICAL ELEMENTS. Support the furnace on the rafters, floor, or platform with the air handler. If using a platform make it large enough to support the entire furnace and air handler. Rest the platform on the floor or hang it with chains or cables. Refer to Bulletin for mounting instructions. For round metal plenum systems, use the correct diameter metal pipe adapter for you plenum size. For example the 1218 and 2430 systems typically use 7-inch (178 mm) and the 4860 systems use 10-inch (254 mm) diameter pipe. Figure 5 shows the installation of the Plenum adaptor (10- inch round plenum adaptor is provided). Electric Furnace The furnace also includes a 9½ 9½-inch ( mm) square plenum adaptor. If the plenum is smaller, then use a reducer fitting. Fiberglass reducers are available to reduce the 9½-inch (241-mm) square duct to 8½-inch (216-mm) or 6½-inch (165-mm) square duct (see Table 7). Alternately, the reducer can be eliminated if you use a smaller adapter (see Table 6). The adapters are designed to fit inside the square duct and are secured with sheet metal screws and washers. The joint should then be sealed per UL-181A-M (see Figure 7). Square Fiberglass Reducer Note: All metal connections must be mechanically fastened with sheet metal screws and the joints and seams must be taped with UL-181-A-P foil faced tap or sealed with duct mastic. Plenum Adaptor Electric Furnace Plenum Adaptor 1 1/2" (38-mm) flat head sheet metal screws and 1" (25 mm) O.D. washers Fiberglass Reducer Plenum Adapter IL00377.CVX UL 181A-M Mastic Closure Figure 5. Start Collar Installation IL00381.CVX Always allow a minimum of 24 inches (610 mm) of straight duct between the outlet of the electric furnace and any tee or elbow. Figure 6 shows an illustration of this minimum distance required between the electric furnace and any elbows or tees. Elbow or Tee 24 [610] minimum Electric Furnace Air Handler Figure 7. Square Duct Installation (Furnace shown with optional square plenum adapter) Insulate all metal ducting with 1.5-inch (38-mm) minimum fiberglass insulation. For round duct use either sleeve insulation or foil-faced duct wrap. For square duct use either fiberglass duct board or foil-faced duct wrap. Tape all seams to prevent air leaks. When the furnace is installed in high humidity areas, such as an unconditioned attic or crawlspace, there is a possibility of condensation forming on the furnace cabinet surfaces during the cooling mode. To prevent condensation, cover the furnace with 1-inch (25-mm) foil faced fiberglass insulation or duct board. Allow for access to the control box cover for servicing. Tape all seams with UL 181-A-P aluminum tape. Dimensions inches [mm] IL00068a.CVX Figure 6. Location (top view) Copyright 2005 Unico, Inc.

128 Bulletin Page 4 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. For single-phase furnaces, use the 15 amp breaker integrated into the furnace for the air handler power supply. For three-phase furnaces, use a separate singlephase 208/240V, 60 Hz power supply with appropriate amp fuse or breaker and wire gauge for the air handler. When using a Unico electric furnace it will be necessary to mount the blower control box on top of the blower cabinet or remote mount the blower control box. Wire the air handling unit in accordance with Bulletin 30-20, Installation Manual for M Series Modular Air Handler Units, Bulletin 30-24, Installation Instructions for M Series Modular Heat Pump System, or Bulletin 30-10, Installation Manual for M1218 Fan Coil. Open the furnace cover and connect the power supply to terminals L1 and L2 on the high voltage terminal block. Use Table 2 to select the correct wire gauge for the specific amperage of the furnace being installed. Connect a ground wire to ground lug, labeled G. Terminals W1 and W2 on units are for power to the blower. Connect the 24V control wiring as shown in Figures 9 and 10. Use Figure 8 for heating-only or heating-cooling systems. Use Figure 9 for heat pump systems. If using the Unico Advanced Control Board controller refer to the Advanced Control Manual for 24V control wiring diagrams. All furnaces below 20 kw are internally wired to provide 5 kw of defrost heat. The 20 kw furnace provides 10 kw of defrost heat. If 10 kw of heating during defrost is desired for the smaller kw furnaces, contact the Unico Engineering Office for instructions. It is important to use a thermostat designed for use with electric heat, as a normal HEAT-COOL thermostat will not energize the fan. Thermostats designed for heat pump systems will also work. Match thermostat anticipator settings for combined amperage load of all components, including electric furnace contactors, to prevent damage to thermostat. The internal wiring diagrams are shown in Figures 10 through 15. Special Wiring for Heat Pumps If used with a heat pump, it may be necessary to install an outdoor thermostat. Refer to Table 3 to determine if your system requires an outdoor thermostat. The outdoor thermostat will shut down the last step to prevent the furnaces from cycling on high limit. It is recommended to set the thermostat at 30 F (-1 C). As an option for the 15 and 20 kw furnaces for enhanced energy savings, a second outdoor thermostat, set at around 40 F (4 C) may be installed to limit the use of the second step. For units using the Unico Advanced Control Board no thermostats are required. The Unico Advanced Control Table 3. When to use outdoor thermostat for last stage furnaces. Airflow kw Rating of Electric Furnaces CFM (m 3 /s) (.19) N/A N/A N/A 500 (.24) N/A N/A 600 (.28) N/A 700 (.33) N/A 800 (.38) 900 (.42) 1000 (.47) 1250 (.59) Outdoor thermostat not required Use outdoor thermostat to limit last stage element Board will lock out the third stage of the electric furnace when the heat pump is on. Duct Design The design of the duct system must account for the added restriction of the furnace. Table 4 lists the static pressure drop of the furnaces. Usually, it will be necessary to add additional outlets to account for the added restriction, particularly for the systems requiring more than 800 cfm (380 L/s). For these systems it is not unusual to have 7 outlets per ton. Table 4. Pressure drop, inches of water (Pa) Model, Nominal kw (.19) 0.04 (10) 0.09 (22) 0.09 (22) 0.13 (32) 0.17 (42) 500 (.24) 0.05 (12) 0.10 (25) 0.10 (25) 0.14 (35) 0.19 (47) Airflow, CFM (m 3 /s) 600 (.28) 0.05 (12) 0.11 (27) 0.11 (27) 0.16 (40) 0.21 (52) 700 (.33) 0.06 (15) 0.11 (27) 0.11 (27) 0.16 (40) 0.22 (55) Sequence of Operation 800 (.38) 0.06 (15) 0.12 (30) 0.12 (30) 0.18 (45) 0.24 (60) 1000 (.47) 0.08 (20) 0.16 (40) 0.16 (40) 0.23 (57) 0.31 (77) 1250 (.59) 0.12 (30) 0.25 (62) 0.25 (62) 0.37 (92) 0.49 (122) All furnaces have a built-in delay feature to delay the furnace from coming on before the air handler is operating. There is no delay off. As soon as the thermostat is satisfied, the furnace de-energizes and the air handler blower will continue running for approximately 1 minute. The furnace is designed for a softer start so that there is a short time delay between stages. Copyright 2005 Unico, Inc.

129 Bulletin Page 5 Capacity at Lower Voltages The elements are rated at 240 Volts and should not be used at higher voltages. Lower voltages are acceptable. However, furnaces are resistive loads so capacity is reduced by the square of the voltage ratio. kw (output) = kw (rated) x (V/240) 2 Therefore, use the multiply the rated capacity by the factor shown in Table 5 to determine the actual output of the furnace at other voltages. Table 5. Furnace Capacity Factor at other voltages. Voltage Factor Optional Adaptors and Spare Parts Table 6 provides a list of optional plenum adaptors available for the electric furnace listed in Tables 6 and 7. Spare parts are also listed in Table 8 and can be ordered using the part numbers shown. Table 6. (Optional) Plenum Adaptors Adaptor Size Part Number 7-inch [178 mm] Round A inch [228 mm] Round A inch [254 mm] Round* A inch [165 mm] Square A inch [216 mm] Square A inch [241 mm] Square* A *Included with unit Table 7. (Optional) 1 inch (25 mm) Fiberglass Square Reducers Part No. Square Size UPC S 9.5 to 8.5 inch [241 to 216 mm] UPC S 9.5 to 6.5 inch [241 to 165 mm] UPC S 8.5 to 6.5 inch [241 to 216 mm] Table 8. Spare Parts List Part Description Part Number Fuse Link A Auto Limit A Sequencer (1 Pole) A Sequencer (2 Pole) A Contactor (1 Pole) A Contactor (2 Pole) A Fan Interlock Relay A Circuit Breakers 2-Pole 15 Amp (Blower Breaker) 2-Pole 25 Amp (WON0502) 2-Pole 40 Amp (WON0752) 2-Pole 50 Amp (WON1002,1502,2002) 3-Pole 15 Amp (WON0504) 3-Pole 25 Amp (WON0754) 3-Pole 30 Amp (WON1004) 3-Pole 40 Amp (WON1504) A A A A A A A A Copyright 2005 Unico, Inc.

130 Bulletin Page 6 CONTROL WIRING DIAGRAM FOR COOLING ONLY UNICO SYSTEM WITH ELECTRIC HEAT HONEYWELL T87F T-STAT WITH Q539J SUBBASE (OR EQUIVALENT COOLING WITH ELECTRIC HEAT THERMOSTAT) COMMON HEAT COMPRESSOR POWER FAN X W Y B R O G P UNICO SYSTEM AIR HANDLER OUTDOOR CONDENSING UNIT Y C POWER COMMON 1 1 WUN ELECTRIC DUCT HEATER FAN INTERLOCK DEFROST HEAT STEP 1 (5 kw AND UP) STEP 2 (10 kw AND UP) STEP 3 (15 kw AND UP) COMMON 1 TO REDUCE HEATING CAPACITY AND PREVENT SHORT CYCLING IN MILD WEATHER, INSTALL AN OUTDOOR THERMOSTAT IN CIRCUIT. IL00042A.CVS Figure 8. Control Wiring Diagram for Heating-Only or Cooling/Heating Applications CONTROL WIRING DIAGRAM FOR UNICO HEAT PUMP WITH WUN ELECTRIC DUCT HEATER HONEYWELL Y594R1514 THERMOSTAT OR EQUAL UNICO SYSTEM AIR HANDLER OUTDOOR CONDENSING UNIT WUN ELECTRIC DUCT HEATER FAN G 1 1 FAN INTERLOCK L 2 W DEFROST HEAT 2 DEFROST HEAT COMPRESSOR Y 3 3 STEP 1 (5 kw AND UP) REV. VALVE (COOLING) O 4 O REV. VALVE 1 4 STEP 2 (7.5 kw AND UP) POWER R 5 R POWER 1 5 STEP 3 (15 kw AND UP) REV. VALVE (HEATING) B 2 6 Y COMPRESSOR 6 COMMON X 7 X COMMON 7 COMMON EMER. HEAT E AUX. HEAT W2 AUX. HEAT W3 1 2 TO REDUCE HEATING CAPACITY AND PREVENT SHORT CYCLING IN MILD WEATHER, INSTALL AN OUTDOOR THERMOSTAT IN CIRCUIT. WIRING DIAGRAM AS SHOWN IS FOR A REVERSING VALVE THAT IS ENERGIZED IN COOLING MODE. WHEN VALVE IS ENRGIZED IN HEATING MODE, USE THE "B' TERMINAL ON THE THERMOSTAT, INSTEAD OF THE "O" TERMINAL. IL00056A.CVS Figure 9. Control Wiring Diagram for Heat Pump Applications Copyright 2005 Unico, Inc.

131 Bulletin Page 7 FAN DEFROST HEAT STEP 1 CONTROL TERMINAL BLOCK GRN BRN RED FAN INTERLOCK RELAY ORG COMMON ORG ORG INTERLOCK/TIME DELAY Control Wiring Power Wiring RED SEQUENCER ORG RED BRN BRN CONTACTOR ORG CIRCUIT BREAKERS L1 ELEMENT #1 FUSE LINK *L 165 To Blower L2 25 A. M1 M2 15 A. G GROUND LUG G IL00057a.cs Figure 10. Internal Wiring Diagram for WON0502. CONTROL TERMINAL BLOCK FAN GRN BRN DEFROST HEAT RED STEP 1 BLK STEP 2 FAN INTERLOCK RELAY ORG COMMON ORG ORG RED INTERLOCK/TIME DELAY SEQUENCER ORG Control Wiring Power Wiring RED BRN BLK BRN CONTACTOR ORG ELEMENT #1 FUSE LINK *L 165 CONTACTOR ORG CIRCUIT BREAKERS L1 L2 40 A. M1 * ELEMENT #2 FUSE LINK *L 165 To Blower M2 15 A. G GROUND LUG G * WON07502R10-40 A. Circuit Breaker WON1002R10-50 A. Circuit Breaker IL00058a.CVS Figure 11. Internal Wiring Diagram for WON0752 and WON1002. Copyright 2005 Unico, Inc.

132 Bulletin Page 8 CONTROL TERMINAL BLOCK FAN DEFROST HEAT STEP 1 STEP 2 STEP 3 COMMON GRN BRN RED BLK BLU ORG FAN INTERLOCK RELAY ORG ORG INTERLOCK/TIME DELAY RED RED SEQUENCER ORG BRN Control Wiring Power Wiring BLK SEQUENCER BLK ORG BLU BRN CONTACTOR ORG ELEMENT #1 FUSE LINK *L 165 CONTACTOR ORG CIRCUIT BREAKERS L1 ELEMENT #2 FUSE LINK *L 165 L2 50 A. CONTACTOR ORG L1 ELEMENT #3 FUSE LINK *L 165 L2 25 A. M1 To Blower M2 G 15 A. GROUND LUG IL00059a.CVS G Figure 12. Internal Wiring Diagram for WON1502 CONTROL TERMINAL BLOCK FAN DEFROST HEAT STEP 1 STEP 2 STEP 3 COMMON GRN BRN RED BLK BLU ORG FAN INTERLOCK RELAY ORG ORG INTERLOCK/TIME DELAY RED RED SEQUENCER ORG BRN Control Wiring Power Wiring BLK SEQUENCER BLK ORG BLU BRN CONTACTOR ORG ELEMENT #1 FUSE LINK *L 165 ELEMENT #2 FUSE LINK *L 165 CONTACTOR ORG ELEMENT #3 FUSE LINK *L 165 CIRCUIT BREAKERS L1 L2 50 A. CONTACTOR ORG L1 ELEMENT #4 FUSE LINK *L 165 L2 50 A. M1 To Blower M2 G 15 A. GROUND LUG IL00060a.CVS G Figure 13. Internal Wiring Diagram for WON2002. Copyright 2005 Unico, Inc.

133 Bulletin / June 2003 Service Report Customer Address Today s Date Installed Date Phone Fax Dealer/Contractor Phone Fax Distributor/Branch Phone Fax Installed Equipment Air Handler Model: M1218 M2430 M3642 M4860 Hot Water Coil WUN circle one Nominal Capacity tons kw Condenser Make/Model SEER Serial No(s): Blower Module Cooling Module Heating Module Installed Options: Filter Drier Low Ambient Control Mild Weather Kit (for heat pumps) Liquid Line (size, length) Suction Line (size, length) No. of outlets Plenum Duct (size, length, type) Return Duct (size, length, description) Duct System (Use back of sheet to sketch) Avg. Length (ft.)(mm) Field Measurements Electrical: Amps: Volts Total Airflow (using TurboMeter) Motor Model Number (See Nameplate) Airflow (from Amperage Table) circle one CFM L/s circle one CFM L/s Plenum Static Pressure circle one in. water Pa Where measured: (min. of 24 inch [600 mm] from blower) circle one Pressures: psig kpa Suction Line Liquid Line Location measured: OUTDOOR UNIT INDOOR UNIT Temperatures: Suction Line Liquid Line Location measured: OUTDOOR UNIT INDOOR UNIT circle one F C Superheat Subcooling Refrigerant Charge (lbs. oz.) Water coil data: Outdoor Ambient Return Air Supply Air T (coil) circle one GPM L/s Water temperature (inlet/outlet): / circle one F C Glycol Percentage: Comments or Description of Problem Report Filed By: *IMPORTANT* COMPLETELY FILL-IN BOTH SIDES OF THIS REPORT Copyright 2003 Unico, Inc.

134 Bulletin Page 2 Duct Run Duct Length, ft (mm) Room TurboMeter Knots Delivered Airflow, CFM=knots x 2 (L/s=knots x 0.94) Set to the first click on the TurboMeter. This is the knots setting (or 100s of ft/min or m/s x 0.51). Multiply the TurboMeter reading by 2 to get CFM (or use L/s = knots). Required Room Load Cooling Please make a sketch of the plenum system showing elbows, length and size of duct, and location of branch runs. Heating Copyright 2003 Unico, Inc.

135 Bulletin / November 2004 Note Specifications, ratings, and dimensions subject to change without notice. Copyright 2004 Unico, Inc.

136 Bulletin Page 2 Electrical Data Refrigerant Approx. Nominal Sound Model Number Capacity, Min. Max. Fuse/ Shipping level*, db Amps Charge, Btu/hr [kw] Circuit Circuit Voltage Hz Phase Type Weight, lb. [kg] Ampacity Breaker [kg] UCHR P 36,000 [10.6] [2.3] 310 [141] 208/ UCHR P 60,000 [17.6] [3.6] 340 [154] 69 R-22 UCHR P 36,000 [10.6] [2.3] 310 [141] 50 UCHR P 60,000 [17.6] [3.6] 340 [154] * Sound measurement taken at 3feet from the front of the unit. Pump Data Other Data Model Number Min Req. Flow Rate, GPM [L/s] Max Flow Rate, GPM [L/s] Head Press at Min. Flow Rate*, ft. water [kpa] Pump Size, HP [W] Pump Speed, RPM Supply Water Temp, F [ C] Min. System Volume, Gal. [L] Approx. Chiller Volume, Gal. [L] Minimum Expansion Tank Size**, Gal. [L] UCHR P 7.2 [0.6] 50 [149.5] ¾ [560] UCHR P 12 [0.9] [134.5] 1-1/3 [1007] UCHR P 7.2 [0.6] [0.9] 50 [149.5] ¾ [560] UCHR P 12 [0.9] 45 [134.5] 1-1/3 [1007] *Evaporator pressure drop is included. ** Not included, field installed [6.7] 25 [95] 1.0 [3.8] 1.0 [3.8] COOLING PERFORMANCE Performance*** Model UCHR P (60 Hz) UCHR P (50 Hz) Outside Temperature Capacity Power Input Efficiency Capacity Power Input Efficiency F [ C] Btu/hr [kw] W EER [COP] Btu/hr [kw] W EER [COP] , , , , , , , , , , *** Based on compressor data. At 44ºF leaving water temperature and minimum required flow rate. Performance*** Model UCHR P (60 Hz) UCHR P (50 Hz) Outside Temperature Capacity Power Input Efficiency Capacity Power Input Efficiency F [ C] Btu/hr [kw] W EER [COP] Btu/hr [kw] W EER [COP] , , , , , , , , , , *** Based on compressor data. At 44ºF leaving water temperature and minimum required flow rate. HEATING PERFORMANCE Performance*** Model UCHR P (60 Hz) UCHR P (50 Hz) Outside Temperature Capacity Power Input Efficiency Capacity Power Input Efficiency F [ C] Btu/hr [kw] W EER [COP] Btu/hr [kw] W EER [COP] , , , , , , , , , , , , *** Based on compressor data. At 120ºF leaving water temperature and minimum required flow rate. Performance*** Model UCHR P (60 Hz) UCHR P (50 Hz) Outside Temperature Capacity Power Input Efficiency Capacity Power Input Efficiency F C Btu/hr [kw] W EER [COP] Btu/hr [kw] W EER [COP] , , , , , , , , , , , , *** Based on compressor data. At 120ºF leaving water temperature and minimum required flow rate.

137 Bulletin Page 3 Operating Range COOLING HEATING 20* to 115ºF (-7 to 46ºC) outside 10 to 70ºF (-10 to 21ºC) outside Normal Operating Range temperature temperature Water Temperature Range 38 to 60ºF (3 to 16ºC) Up to 125ºF (52ºC) * Use a low ambient kit and replace the low pressure switch with a psig switch when operated below 65ºF (18ºC). Chiller Dimensions Figure 1 shows the overall dimensions of the Unichillers. All sizes and models have the same dimensions [464] 37.5 [953] [1162] 4.9 [124] 1-inch MPT 1.5 [38] 1.25-inch Knockout 33.4 [849] 2.1 [53] 7.75 [197] 2.00 [51] 11.6 [295] 3.75 [95] 13.1 [333] 3.25 [83] 1-inch MPT Figure 1: Chiller Dimensions

138 Bulletin (October 2004) INSTALLATION, OPERATION AND MAINTENANCE MANUAL Copyright 2004, Unico Inc.

139 Bulletin (October 2004) Page 2 GENERAL... 3 SCOPE... 3 GENERAL PRECAUTIONS AND SAFETY TIPS... 3 UNPACKING... 4 LOCATION... 4 SPECIFICATIONS... 5 PIPING INSTALLATION... 5 Freeze Protection... 6 WIRING... 7 Sequence of Operation... 9 Digital Temperature Controller Operation... 9 SINGLE CHILLER SYSTEMS MULTIPLE CHILLER SYSTEMS Two Chiller Systems without Stage Controller (Special Case) Two or More Chiller Systems with Stage Controller LOW AMBIENT OPERATION TROUBLESHOOTING MAINTENANCE... 17

140 Bulletin (October 2004) Page 3 GENERAL The following information is to help the installer save time, provide the best possible installation and ensure continuous trouble-free operation. SCOPE This manual applies to Unichiller self-contained reverse cycle chillers and cooling only chillers. Both referred to as a chiller unless there is a special instruction. Then the terms reverse-cycle or cooling only will be used. The Unichiller is designed to match all Unico System chilled water coils. It can also be used with conventional air handlers of appropriate size or wall- or ceiling-hung chilled water fan coil units. GENERAL PRECAUTIONS AND SAFETY TIPS!!! Before operating, be sure the unit is properly grounded to prevent injury or death from electrical shock! Disconnect electrical supply before wiring unit to prevent injury or death from electrical shock! Do not handle the top half of the scroll compressor as it operates at a temperature high enough to cause serious injury. Do not operate this system with water alone. A minimum of 10% propylene glycol is essential for proper operation. Do not use any liquid solution other than the solution of water and propylene glycol (mixed in accordance with the specified amount in the Unichiller Design Manual) in the piping system. Pump must be primed (free of air and suction pipe full of liquid) before starting. If pump is run dry, rotating parts will seize and mechanical seal will be damaged. All electrical wiring should be in accordance with the latest edition of the National Electric Code and all local codes and regulations. The unit is safety certified to UL 1995, CAN/CSA STD C22.2 NO. 236 and listed with ETL. All piping must be in accordance with all local codes and ordinances. Installation should be in accordance with all local codes and regulations and with the National Board of Fire Underwriters regulations. In case of conflict, local codes take precedence. These units are designed to operate exclusively with R-22 in a self-contained, pre-charged refrigerant system. Do not access the closed refrigerant system for any reason other than after-sale, after installation component replacement. Such service is to be conducted by qualified personnel only. All units are inspected prior to shipping and are carefully packaged in cartons. Inspect all cartons prior to unpacking. Remove the unit from package and inspect for any visible signs of concealed damage. Notify carrier of any damage.

141 Bulletin (October 2004) Page 4 Clean the cabinet air filters regularly. The filters clean the air cooling the circulation pump. UNPACKING All units are inspected prior to shipping and are carefully packaged in cartons. Inspect all cartons prior to unpacking. Notify carrier of any damage. Open the carton to remove the unit. Inspect unit for any visible 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. LOCATION When selecting a location for the chiller, keep the following in mind: The minimum required clearances are 24 inches on the service access side, 12 inches for air inlets on all sides and 60 inches for air discharge side (see Figure 1). TOP VIEW FRONT VIEW 12 inches (0.3 m) air inlet 12 inches (0.3 m) air inlet 6 inches (0.15 m) minimum or 24 inches (0.6 m) for service service access side Overhang 24 inches (0.6 m) 12 inches max (0.3 m) 60 inches (1.5 m) air discharge shrubs or porous wall Maximum height of wall is 4.5 ft (1.4 m) IL00349.CNV Figure 1: Unichiller Clearances The chiller is an outdoor unit and must be located outdoors. It cannot be connected to condenser air with ductwork, or placed inside a room. Locate the chiller cabinet at a level sufficiently above grade to prevent ground water from entering. In areas with heavy snow, further elevation may be necessary. Installing unit in a pit will degrade performance. In some cases, use of air deflectors is necessary. Contact factory for specific recommendations. When installing near salt water, the best location is on the shore side of the building. To improve longevity, coat the fins with Adsil fin coating or equal. * Adsil is a registered trademark of Adsil, Palm Coast, FL.

142 Bulletin (October 2004) Page 5 SPECIFICATIONS Table 2: Unichiller Electrical Specifications Model Number Power (Hz/Phase/Volts) Minimum Circuit Ampacity Max. Fuse/ Circuit Breaker Compressor Fan Motor Pump RLA LRA RLA HP RLA HP UCHR P 60/1/ ¾ 0.40 UCHR P 60/1/ /3 1/6 UCHR P 50/1/ ¾ 0.32 UCHR P 50/3/ /3 Available Head Rated Flowrate: 50 ft water (3 ton) 45 ft water (5 ton) Nominal Capacity: Design water flowrate: Minimum water flowrate: Maximum flowrate: Pump Inlet/Outlet: 36,000 Btu/h (3 ton) 60,000 Btu/h (5 ton) 2.4 gpm/ton 2.0 gpm/ton 14 gpm 1 MPT COOLING HEATING 20* to 115ºF (-7 to 46ºC) 10 to 70ºF (-10 to 21ºC) outside Normal Operating Range outside temperature temperature Water Temperature Range 38 to 60ºF (3 to 16ºC) Up to 125ºF (52ºC) * Use a low ambient kit and replace the low pressure switch with a psig switch when operated below 65ºF (18ºC). PIPING INSTALLATION All piping must be in accordance with all local codes and ordinances. All threaded piping must be sealed with pipe sealant (e.g. Teflon tape) to prevent leaks. Install the strainer provided with the Unichiller on the suction of the pump. Then connect the supply and return piping per Figure 2 and UnichillerRC Design Manual. Install the drain at the lowest point of the system and the vent at the highest point of the system. Isolation valves may also be installed for the air handlers. Adjust the flow rates and balance the system using the appropriate valves in the piping. Refer to UnichillerRC Design Manual for more piping information.

143 Bulletin (October 2004) Page 6 SINGLE AIR HANDLER Isolation Valve MULTIPLE AIR HANDLERS Check valve ( required only for multiple chill er applications) Flowmeter (optional) Bypass loop Air Handler Unichiller ( pump included) Air Handler Air Handler Strainer B A AB Balancing Valve Isolation Valve Expansion Tank Storage Tank IL CNV Figure 2: Unichiller Basic Piping Schematic Freeze Protection The liquid solution is a water-propylene glycol mixture. A minimum of 10% propylene glycol is strongly recommended. Refer to the Unichiller Design Manual for guidelines.

144 Bulletin (October 2004) Page 7 WIRING!! Before operating, be sure the unit is properly grounded to prevent injury or death from electrical shock! Disconnect electrical supply before wiring unit to prevent injury or death from electrical shock! All electrical wiring should be in accordance with the latest edition of the National Electric Code and all local codes and regulations. The unit is safety certified to UL 1995, CAN/CSA STD C22.2 NO. 236 and listed with ETL. Unichiller reverse cycle wiring ladder and pictorial diagrams are shown in Figures 3 and 4, respectively. Figure 3: Unichiller Reverse Cycle Wiring Ladder Diagram

145 Bulletin (October 2004) Page 8 Figure 4: Unichiller Pictorial Wir ing Diagram

146 Bulletin (October 2004) Page 9 Sequence of Operation OFF MODE (UCHR only): There is no power going to the unit when the unit is in this mode. COOLING MODE: When power is applied from the circuit COOL breaker, the control transformer is energized. The pump bypass timer (10 second timer) temporarily bypasses the flow switch. The pump starts to move the liquid solution if the system is properly HEAT OFF filled and air purged. The digital temperature controller is also activated when the pump is energized. If after 10 seconds the flow switch shuts off for any reason, the system will stop and must be manually re-energized. If the temperature controller calls for cooling, then the compressor and the fans are energized. HEATING MODE (UCHR only): When the power is applied from the circuit breaker, the control transformer is energized. The reversing valve is also energized, reversing the flow of the refrigerant to make hot water. The pump bypass timer (10 second timer) temporarily bypasses the flow switch. The pump starts to move the liquid solution, if the system is properly filled and air purged. The digital temperature controller is also activated when the pump is energized. If after 10 seconds the flow switch shuts off for any reason, the system will stop and must be manually re-energized. If the temperature controller calls for heating, then the compressor and the fans are energized. In the heating mode, there is a defrost mode, which is based on the surrounding air temperature. In the defrost mode, the direction of the refrigerant flow is reversed to direct hot refrigerant through the condensing coil to prevent the excessive frosting of the coil. The defrost mode is terminated when the temperature of the condensing coil exceeds the fieldselectable termination temperature (50, 60, 70 or 80ºF). The default termination temperature is 70ºF, therefore, the defrost mode will terminate when the coil temperature reaches 70ºF. In a colder climate, the setting can be raised to ensure the defrosting of the coil. Similarly, in a warmer climate, the setting can be lowered so that the unit is not in the defrost mode longer than it needs to. There is a five-minute time delay after each time the compressor is shut down. The pump will run continuously in the cooling and heating modes unless the flow switch opens or the power supply is disconnected. Digital Temperature Controller Operation The temperature controller is a two-stage controller with a liquid crystal display (LCD). Stage 1 is used for heating (factory set at 120ºF with 10ºF differential) and Stage 2 (factory set at 44ºF with 10ºF differential) is used for cooling. Follow the instructions below to change the settings if different temperatures are desired. There are three keys on the face of the control: SET,,. Step 1: To start programming, press the SET key once to access Fahrenheit/Celsius mode. The display will show the current status,

147 Bulletin (October 2004) Page 10 either F for degrees Fahrenheit or C for degrees Celsius. Then press the up or down arrow key to toggle between F and C. Stage 1 (Heating) Step 2: Press the SET key again to access the stage 1 setpoint. The LCD will display the current setpoint and the S1 annunciator will be blinking on and off to indicate that the control is in the setpoint mode. Then press either the up arrow key to increase or the down arrow key to decrease the setpoint to the desired temperature. Step 3: Press the SET key again to access the stage 1 differential. The LCD will display the current differential and the DIF1 annunciator will be blinking on and off to indicate that the control is in the differential mode. Then press either the up arrow key to increase or the down arrow key to decrease the differential to the desired setting. Step 4: Press the SET key again to access the stage 1 cooling or heating mode. The LCD will display the current mode, either C1 for cooling or H1 for heating. Then press either the up arrow key or down arrow key to set at H1 for heating. Stage 2 (Cooling) Step 5: Press the SET key again to access the stage 2 setpoint. The LCD will display the current setpoint and the S2 annunciator will be blinking on and off to indicate that the control is in the setpoint mode. Then press either the up arrow key to increase or the down arrow key to decrease the setpoint to the desired temperature. Step 6: Press the SET key again to access the stage 2 differential. The LCD will display the current differential and the DIF2 annunciator will be blinking on and off to indicate that the control is in the differential mode. Then press either the up arrow key to increase or the down arrow key to decrease the differential to the desired setting. Step 7: Press the SET key again to access the stage 2 cooling or heating mode. The LCD will display the current mode, either C2 for cooling or H2 for heating. Then press either the up arrow key or down arrow key to set at C2 for cooling. SINGLE CHILLER SYSTEMS Single chiller systems can be controlled using the digital temperature controller inside the chiller or a thermostat. If the chiller will be controlled using the temperature controller, then no modifications are necessary to the wiring. The setpoint and differential temperatures can be adjusted using the steps explained above if settings other than the default values are needed. The chillers are wired so that the pump runs constantly when the switch is in cool or heat position. Figure 5a shows how to re-wire the system to turn on/off the pump with the room thermostat rather than running it all the time. To add this feature, a White-Rodgers (Steveco) Model Two Pole Double Throw relay or equal must be added to the system as shown in Figure 5a. First, connect the compressor terminal (Y) and the Unico Air Handler terminal 7 relay coil. Then connect the air handler valve to one set of normally open contacts on the relay (usually terminals 1 and 3); this will open the valve and let water flow through the indoor coil when the system calls for heat or cool. The other set of contacts is used to power the chiller, including the pump. Connect terminals 4 (common) and 6 (normally open) of the

148 Bulletin (October 2004) Page 11 relay to the transformer in the Unichiller as shown in Figure 5a. This method uses the selector switch to switch between cool and heat modes. THERMOSTAT White-Rodgers Thermostat Model 1F CONTROL WIRING DIAGRAM CHANGES FOR UNICHILLER WITH PUMP CONTROL FAN HEAT COMPRESSOR POWER COMMON G W Y R X UNICO SYSTEM AIR HANDLER DPDT RELAY Steveco Relay plus Enclosure ( or equal) VALVE UNICHILLER (See Detail A) B A 5 6 VALVE 7 Detail A Cut wire A B BLUE OR 24 V 240 V YL BLK Transformer EL00024a.CVX Figure 5a: Wiring Schematic of Pump Control with a Two-Pole Relay Another option is to control entire chiller operation from the thermostat. This method eliminates the use of the selector switch. The thermostat is used to turn on the pump and to switch between cool and heat modes. To eliminate the selector switch a double-pole, double-throw relay (Steveco or equal) must be added as shown in Figure 5b. A heat pump thermostat (White-Rodgers Model 1F or equal) is used. Disconnect selector switch wires from terminals 2 (blue), 3 (black) and 9 (red) of the Unichiller. Connect terminal 2 (Unico Air Handler) to terminal 9 (Unichiller), terminal 6 (Unico Air Handler) to terminal 3 (Unichiller), terminal 7 (Unico Air Handler) to terminal 8 (Unichiller). Connect terminals 6 and 7 of the Unico Air Handler to the coil of the relay. Connect one set of normally open contacts of the relay to the indoor coil. Connect the second set of normally open contacts of the relay to terminals 2 and 3 of the Unichiller. Connect terminals B (reversing valve), R (power), Y (compressor) of the thermostat to terminals 2, 5 and 6 of the Unico Air Handler, respectively.

149 Bulletin (October 2004) Page 12 THERMOSTAT White-Rodgers Thermostat Model 1F FAN G UNICO SYSTEM AIR HANDLER 1 Di sconnect #1(Black Wire) and #2 (Blue Wire) of Selector Switch Disconnect #3 ( Red Wire)of SeectorSwtch l i UNICHILLER-RC TERMINAL BLOCK HEAT REV. VALVE POWER COMMON COMPRESSOR W B R X Y VALVE VALVE ( Indoor Coil) 6 DPDT RELAY Steveco Relay plus Encl osure ( or equal) EL00085a. CVX Figure 5b: How to Control the Unichiller-RC with Thermostat Two-Transformer System MULTIPLE CHILLER SYSTEMS Two Chiller Systems without Stage Controller (Special Case) Although the best method of staging two-chiller systems is using a stage controller, it can also be accomplished by selecting the proper differential setpoints. Both chillers must be set at different differentials and must be greater than 10ºF to prevent short cycling. For example, a two-chiller system with a 3-ton and a 5-ton can be set as follows: Both cooling temperatures set at 42ºF, 3-ton differential set at 12ºF and 5-ton differential set at 10ºF. Two or More Chiller Systems with Stage Controller When installing multiple chillers, use a multiple stage controller. Currently, the most common and readily available stage controllers allow for staging in either cooling or heating mode but not both. Therefore, if you want to stage both heating and cooling modes, you need two stage controllers: one for cooling and one for heating cycle.

150 Bulletin (October 2004) Page 13 The multiple stage controller replaces the liquid chiller controller in the unit. The diagrams in this manual require that the chillers be wired for constant pump operation. If you would also like to stage the chiller pumps with the stage controller, consult to the UnichillerRC Design Manual or contact Unico Customer Service at For up to four-stage control, a controller such as Heat-Timer SQ Series/SEQ-4 (contact Heat Timer for availability) or equal is recommended. The wiring schematic for this controller is shown in Figure 6. Please note that the unused stages must be switched off. Figure 6 shows how to wire a four-stage controller for constant pump operation. Details A and B in Figure 6 shows the changes in the internal wiring of the chiller. Disconnect and remove the digital temperature controller (DTC) from the chiller (shown in Detail B). Connect the cooling stage controller to terminal 6 of the heat relay and to terminal 6 of the terminal block. Connect the heating stage controller to terminal 4 of the heat relay and to terminal 6 of the terminal block. Each Unichiller is connected to a different stage. Install the sensors of each stage controller on the system s main pipe.

151 Bulletin (October 2004) Page 14 CONTROLLER WIRING (COOLING) Main Pipe CONTROLLER WIRING (HEATING ) SEQ-4 Unused stages must be swi tched off Cooling Sensor Heating Sensor SEQ-4 Unused stages must be swi tched off Stage Stage B Stage C Stage D A NO C C NO NO C C NO NO C C NO NO C C NO AUX Stage Stage B Stage C Stage D A NO C C NO C C NO NO C C NO NO C C NO NO AUX Ground 115V, 60Hz Input from separate branch ckt A C A C UNICHILLER (See Detail A) To additional device I.E. Secondary pump, combustion air dam per, etc. To additional device I.E. S econdary pump, combustion air dam per, etc. Ground 115V, 60Hz Input from separate branch ckt B C B C UNICHILLER (See Detail B) To additional device I.E. Secondary pump, com bus tion air damper, etc. To additional device I.E. Secondary pump, combustion air dam per, etc. CHILLER INTERNAL WIRING Detail A DISCONNECT DTC Detail B 4 6 Heat Relay B A DTC 5 2 RHE AT 6 4 C C COOL HEAT NO NO 5 COOL 6 C NO 2 RHE AT 4 HEAT C NO Terminal Block C HPS HPS Disconnect digital temperature controller and connect the stage controllers as shown Figure 6: Wiring Schematic of a Four-Stage Controller With Two Stage Controllers & Constant Pump Operation LOW AMBIENT OPERATION EL00037b. CNV To operate the chiller at outdoor temperatures below 65 F (18 C), install a low ambient (fan cycle) control and replace the existing psig low pressure switch with a psig low pressure switch. This will allow operation down to 20 F (-7 C) outdoor temperature. A wind guard may be necessary for operation at windy conditions. Figure 7 applies to Ranco Fan Cycle Control MPF-7009 or equal installed to UnichillerRC. The fan cycle control will shut down both of the fans to maintain the head pressure. The fan cycle control opens when high pressure refrigerant side is at 190 psig (1310 kpa) and resets at 275 psig (1896 kpa). Install the switch on the high pressure refrigerant side. Install a single-pole, double-throw relay (White-Rodgers or equal) inside the UnichillerRC control box next to the terminal block. Disconnect the fan motor lead connecting to the T1 terminal of the contactor and connect it to one of the normally closed

152 Bulletin (October 2004) Page 15 contacts and one of the normally open contacts of the relay. Then connect one of the low ambient controller leads to the other normally closed contact of the relay. Connect the other lead of the low ambient control to terminal T1 of the contactor. Connect the other normally open contact to T1 of the contactor. Connect the relay coil contacts to terminals 8 and 9 on the terminal block. UNICHILLERRC - LOW AMBIENT CONTROL WIRING C Compressor L1 L2 CON T1 T2 Fan 2 ( Defrost Timer Board) Low Ambient Control Termi na l Block SPDT ( White-Rodgers or equal) Figure 7: Wiring Schematic of a Low Ambient Control Kit Both fans on/off EL00026b.C NV

153 Bulletin / February 2001 Quik-Sizer Instructions The Quik-Sizer form, along with the following instructions, is designed to complete a system bid in no more than 1 hour after the Survey is completed. If the bid results in a sale, a more detailed room-by-room heat loss/gain and system layout should be completed using the more detailed instructions included in Bulletin 40-40, System Sizing and Layout Procedure. If needed, information on the climatic conditions of your area can be obtained from your local weather bureau, the ASHRAE Fundamentals Handbook, or the ACCA Manual J. STEP 1: 1) Complete the Job Survey Form, paying close attention to the following: a) Direction the Structure faces. b) Number of Occupants. c) Insulation. d) Type Windows. e) Available Electric Service. f) Location of Main Box. STEP 2: 1) Make a rough sketch of the structure. It is important to obtain whole house and individual room dimensions as you will need them in later steps. STEP 3: 1) Using the information collected in Step 1, calculate the Whole House Heat Gain using ACCA Manual J or ASHRAE Cooling and Heating Load Calculation Manual. 2) Geographical Wet Bulb can be obtained from the local Weather Bureau, from the ACCA Manual J booklet, or from the ASHRAE Climate tables. 3) Once you obtain this factor, it will generally remain the same for you Geographical area. STEP 4: 1) Refer back to the sketch you made in Step 2. 2) Determine the number of outlets required for each room by using the Quik-Sizer Form page 2 of this bulletin. 3) Position the outlets on the sketch using the following guidelines: a) Outlets should be positioned so they do not discharge directly over large pieces of furniture or where people normally sit, walk, or stand. b) Generally, it is best to place outlets near high heat gain areas such as sliding glass doors or large glass areas. c) Most often, outlets can be placed in corners of rooms, directly above light switches, in soffits or next to windows and doors. d) If using floor outlets, positioning should be in the corners of the room or out of the normal traffic pattern. STEP 5: 1) You can now sketch in the Air Handler selected by using the Heat Gain calculated in Step 3. 2) In positioning the Air Handler and Return Air Filter/Grille, the following guidelines should be followed: 3) When possible, first look for an available area inside the conditioned space. A closet, utility room or basement is commonly used. 4) As an alternate, the unit may be placed in the attic over normally non-occupied areas such as a closet, bathroom, or hallway. Never position the unit over a bedroom or sleeping area. STEP 6: 1) You can now sketch in the Plenum Duct System using the following guidelines: (also see Bulletin 30-01, Installation Guide) a) Tees and Elbows should be kept to a minimum. b) It is best to lay out the plenum system to keep the 2 inch (50 mm) supply runs as short as possible. STEP 7: 1) You now have all the information necessary to calculate your job estimate using the Quik-Pricing Section page 4 of this bulletin. Note Specifications, Ratings, and Dimensions are subject to change without notice Unico, Inc.

154 Bulletin UNICO SYSTEM QUIK-SIZER The following chart can be used in estimating the number of runs for a given room. This is for estimating purposes only and should not be a substitute for an accurate room-by-room heat gain calculation and layout. Considerations used for this estimate sheet are as follows: a) Designed for 95 F (35 C) outdoor air and 75 F (24 C) indoor air temperatures. b) 20% of exposed wall is considered window area. c) 6 (150 mm) insulation in attic; 3 (75 mm) insulation in walls. INSTRUCTIONS: 1. Measure room size and length of exposed wall. 2. Figure corner rooms as west exposure. 3. Read across chart relative to direction for number of terminators required per room. 4. Do material take-off in length of tubing and number of runs. Number of Terminators (Outlets) ROOM SIZE w/8 ft (2440 mm) ceiling, EXPOSED WALL ft (mm) NORTH EAST SOUTH WEST (3050 x 3050) 1 1½ 1½ 1½ (3050 x 3660) 1½ 1½ 1½ (3050 x 4270) (3050 x 4880) (3660 x 3050) 1½ 1½ 1½ (3660 x 3660) (3660 x 4270) (3660 x 4880) ½ (3660 x 5490) 2½ 2½ 2½ (3660 x 6100) 2½ 2½ 2½ (4270 x 3050) (4270 x 3660) ½ (4270 x 4270) 2 2½ 2½ (4270 x 4880) 2½ (4270 x 5490) 2½ (4270 x 6100) 2½ 3½ 3½ 3½ (4270 x 6710) 3 3½ 3½ 3½ (4880 x 3660) 2 2½ 2½ (4880 x 4270) 2½ 2½ 2½ (4880 x 4880) (4880 x 5490) ½ (4880 x 6100) 3½ 3½ 3½ (4880 x 6710) (5490 x 3660) (5490 x 4270) (5490 x 4880) ½ (5490 x 5490) 3 3½ (5490 x 6100) 3½ (5490 x 6710) 3½ (6100 x 3660) (6100 x 4270) (6100 x 4880) (6100 x 5490) 3½ (6100 x 6100) (6100 x 6710) Copyright 2001 Unico, Inc. 161

155 Bulletin Job Survey and Quik-Price Form SECTION ONE Customer Name Salesman Address City Telephone Date Sold Date Installed Design Conditions: circle unit of measure F C Winter: Outdoors Indoors Temp. Diff. Summer: Outdoors Indoors Temp. Diff. Remarks: SECTION TWO CONSTRUCTION DETAILS Building Syle: ( ) Single Story ( ) Two Story ( ) Other Direction House Faces: Number of Occupants: Building Situated Over: ( ) Basement ( ) Slab ( ) Other Attic: ( ) Vented ( ) Non-Vented ( ) Average Height ft (mm). Roof: ( ) Pitched ( ) Flat ( ) Other Type Wall Construction: (Specify) Insulation: Walls inches (mm) Ceiling inches (mm) Floors inches (mm) Windows: ( ) Single Pane ( ) Storm Sash ( ) Other Ceiling Height: First Floor ft. (mm) Second Floor ft. (mm) Existing Electrical Service: Amps. Main Box Location: Proposed Condensing Unit Location: Shrubs to move? Pipe Condensate to: Length Refrigerant Lines ft. (mm) Type: Electronic Air Cleaner (Model): Central Humidifier (Model): Remarks: 162 Copyright 2001 Unico, Inc.

156 Bulletin SECTION THREE UNICO SYSTEM RESIDENTIAL QUIK PRICER FORM (Not recommended for Homes Under 1000 Sq. Ft. (93 Sq. m)) A. PEOPLE Use actual number in household, plus at least two. Allow for larger groups if common to entertain. B. Single Story Homes Use lineal feet (mm) of outside wall for space to be conditioned. C. Story and a Half List lineal feet (mm) of first floor outside wall, plus lineal feet (mm) of inside wall (ignore dormers) at floor line of second floor. For item three, enter area of first floor only, but add area of any overhang on second floor, areas over unheated rooms, porches, etc. D. Two Story Use lineal feet (mm) of outside dimension for both first and second floors. For item three, use area of first floor, adding areas of overhangs, and floors over unconditioned rooms on second floor. Item One: Number of People 400 BTUH... BTUH (Number of People 117 Watts... Watts) Item Two: Outside Wall, Total Lineal Feet, Times Appropriate Factor From Table Below. Ft. (Factor)... BTUH TYPE OF WALL ( m. (Factor) (multiplier)... Watts ) VENETIAN BLINDS SHADES OR DRAPES OUTSIDE AWNINGS Single Windows Storm Sash Single Windows Storm Sash Ordinary Wall Insulated Wall Insulated for Elec. Heat Item Three: FLOOR CONDITION Total Living Area (Square Feet), Times Factor Selected From Table Below. Sq. Ft. (Factor)... BTUH ( Sq. m (Factor) 3.15 (multiplier)... Watts ) CEILING CONDITION Uninsulated Attic 2 to 4 Insulation Insulated for Electric Heat Over Basement or Slab on Ground Vented Crawl Space Open Crawl Space Item Four: Multiply floor area (from item three above) times Factor selected from table below. (Refer to either the local weather bureau, the ASHRAE Fundamentals Handbook, or the ACCA Manual J for your area wet bulb design temperature.) Sq. Ft. (Factor)... BTUH ( Sq. m (Factor) 3.15 (multiplier)... Watts ) GEOGRAPHICAL WET BULB CORRECTION FACTOR For 75 F (24 C) Wet Bulb Design Area 1.0 For 78 F (26 C) Wet Bulb Design Area 1.7 For 80 F (27 C) Wet Bulb Design Area 2.7 Item Five: Add All Above Items for Total Heat Gain SECTION FOUR QUIK-PRICING (See Instructions on Price Sheet) (1) Basic System(s), Capacity, at $ : $ BTUH (Watts) (2) Heat, Model, at $ : $ (3) ft., Pre-Charged Tubing, at $ /ft: $ (4A) Single Story Terminators at $ : $ (4B) Two Story Terminators, at $ : $ (4C) Special Terminators, at $ : $ (5) Electrical Service $ (6) Electronic Air Service $ Other $ SUB TOTAL: $ Add Applicable Sales Tax: $ Copyright 2001 Unico, Inc. 163 TOTAL EST. SELLING PRICE: $

157 No. 102 / June 2003 Duct Condensation In areas of high humidity, it is important to take extra steps to ensure that moisture does not condense on the exterior of the supply duct. There are two goals that must be achieved. The duct and connections must be sealed and the R-factor of the duct must be maintained. In most cases our standard sound attenuator (UPC- 26C) and our aluminum supply duct (UPC-25) have sufficient insulation to prevent condensation. However, for extreme humidity conditions or when the local codes mandate, we also offer the sound attenuator with an R-factor of 4.2 and 6.0. The 6.0 R- factor duct also has two vapor seals for added protection in case of punctures in the outer jacket. Condensation occurs only when the surface temperature of the duct falls below the dew point of the ambient air. Under the right conditions just about any duct can be made to sweat. Our duct is no exception, so it is important to take some preventive measures to keep the surface temperature below the expected dew point Most individuals do not know the design dew point but do know the design temperature and relative humidity so it is more convenient to show the maximum relative humidity before condensation will occur. The chart above indicates how more insulation increases the maximum relative humidity allowed. The chart also shows the effect of covering the duct with attic insulation (dotted lines). Even though the R-factor is increased by covering the duct with more insulation, it does not prevent condensation. Without a vapor barrier moisture will easily migrate to a cold surface even if surrounded by insulation. Therefore, it is important not to bury the duct in insulation in an area of high humidity. The following steps will ensure that you minimize or eliminate any potential condensation. 1. Maintain the insulation thickness, even at the seams and joints. Wrap the duct with foam insulation or a larger piece of fiberglass rigid insulation wherever the outer insulation is compressed. Be sure that the insulation has an outer vapor barrier. 2. Always use the tape rings. 3. Use a foam rubber or rigid fiberglass saddle under all hanging straps. 4. Insulate the outside of the tape rings, especially around the terminator with a 2-inch or wider piece of insulation tape. 5. Repair all punctures and rips in the outer jacket. 6. Do not bury the duct in the attic insulation. 7. Seal all metal plenum joints and seams with mastic or aluminum foil UL tape. Use at least 1-inch of fiberglass blanket or sleeve insulation. Be sure the insulation has an outer vapor barrier. 8. Use shiplap joints and seal all rigid round fiberglass plenum joints with either UL heat tape or UL aluminum foil tape. 9. Use gaskets and make sure all take-offs are snug and secure against the plenum. Caulk if necessary. 10. CHECK FOR LEAKS BEFORE BOXING IN THE DUCT. NOTE: The outer jacket of the sound attenuator is the vapor seal. Be especially careful not to puncture or tear the outer mylar jacket. φ - Relative Humidity Supply Duct Maximum Relative Humidity before Condensation Occurs Based on Supply Air of 48 F (9 C) C Duct surrounded by 0.5 inch (1.3 mm) of fiberglass insulation Ambient Temperature, F Insulation Thickness inch (mm) 1.5 (3.8 mm) 1.0 (2.5 mm) 0.75 (1.9 mm) 1.5 (3.8 mm) 1.0 (2.5 mm) 0.75 (1.9 mm) Copyright 2003 Unico, Inc.

158 No. 106/ March 2003 Return Duct System Design Requirements Introduction The Unico System return duct system is a conventional duct system, only smaller because the system uses less air. It is not a high velocity duct system. Every system must have at least one return air register. Typically, this return register is mounted in the ceiling of a central hall near the unit when the unit is mounted in the attic. Sometimes, however, multiple return openings are required, or the single return needs to be in a different location. This Tech Note describes the requirements for designing the return system when a single ceiling mounted return is inadequate. To determine the duct size use the ACCA Manual D or the ASHRAE Handbook Fundamentals and the requirements specified in this note. Requirements Unico has only two requirements: 1. Design the return duct system pressure drop for 0.15 inches of water (37 Pa), including filters. 2. Provide some means of acoustical dampening. IMPORTANT The duct pressure drop and the filter pressure drop added together must be less than 0.15 inches of water. For most systems, the filter pressure drop is approximately 0.10 inches of water (25 Pa) and the duct pressure drop is 0.05 inches of water (13 Pa). Duct Size As for any duct, the size is dependent on duct length, air flow, and allowable static pressure drop. For most systems, the minimum duct size (see Table 1) is sufficient for up to 25 feet (8 m) with no more than three 90 bends. All Unico Return Ducts are 10-ft (3 m) long so if you need a longer duct, add either another section of the Unico Return Duct or a length of plastic core flex duct between the unit and the Unico Return Duct. If you cannot use the Unico Return Duct, either use an acoustically lined sheet metal duct or fiberglass duct board. It can be any shape so long as it has the same equivalent area of the standard duct. If you are using a Electrostatic Table 1. Minimum Duct Size Model Part No. Diameter Length 1218 UPC in. (305 mm) 2430 UPC in. (356 mm) 3642 UPC in. (457 mm) 10 ft. (3 m) 4860 UPC in. (508 mm) Electronic Increasing Pressure Drop Disposable Washable Pleated Table 2. Minimum Filter Size Model Filter Size Filter Type x 20 in. (356 x 508 mm) x 25 in. (356 x 635 mm) x 30 in. (356 x 762 mm) Disposable x 30 in (610 x 762 mm) Filter Type Fig. 1. Typical Filter Pressure Drop Copyright 2003 Unico, Inc.

159 Technote 106 Page 2 rectangular duct, the duct should have the same area. Filter Size The filter size is dependent on the type of filter and the amount of airflow. Typically, a disposable filter has the lowest pressure drop and an electrostatic filter has the greatest pressure drop (see Fig. 1). In some cases, it will be necessary to oversize the filter if it has a high pressure drop. Consult the filter manufacturer for the actual pressure drop at the required airflow. See Tech Note No. 115 for various air cleaning devices for the Unico System. Sound Attenuation Although the Unico air handler is quiet, noise from the blower can travel through the return duct and out the return register, especially when the return duct is short. To reduce the noise transmission, always use an acoustical type of return duct with the return register positioned to eliminate any direct "line-of-sight" from the unit. The standard Unico Return Duct (see Table 1) has a soft porous lining that reduces the noise in the duct. As an alternate, construct the return duct out of fiberglass ductboard or a sheet metal with fiberglass duct lining. To prevent any direct line-of-sight add at least one 90-degree bend in the return. Outside Air The Unico System can accommodate up to 100 percent outside air provided the air is filtered and all water coils are freeze protected if necessary. It is left to the installer to build a transition plenum to connect to the outside duct. See Tech Note No Humidifiers In most applications, a power cold-air humidifier may be installed in the return duct system. Other types of humidifiers should not be used, especially the bypass type or atomizing type. The installer will need to build a return plenum to mount the humidifier. Unico recommends consulting with the humidifier manufacturer on its intended usage prior to selecting the humidifier model and capacity. Do not install a humidifier where freezing can occur unless the humidifier is designed for this purpose. See Tech Note No.109. General Duct Design Practices In addition to the Unico System specific rules in the previous paragraphs, the duct system should always follow basic engineering practices. The following guidelines should be followed whenever possible. 1. Multiple returns should be used when conditioning two or more spaces that do not communicate with each other. This is particularly important when heating and cooling separate floors with doors separating them. 2. Avoid creating a negative pressure zone near gasfired equipment. As an example, do not put a return near a boiler or gas water heater. If the equipment is installed in a basement with a closed door, be sure to install a return for the first floor. 3. It is best to position the return high, near the ceiling, for cooling systems, and low, near the floor for heating systems. When heating and cooling, use two returns, one high and one low. If you can only use one, position it for the most important season. For example if cooling is more important than heating, position the return high. Recognize that one return is not as effective as two for heating and cooling systems 4. An open stairwell behaves like a chimney. Hot air will rise between floors so the heating load for the first floor will be higher than expected from a typical load calculation. Likewise, in cooling the upper floors will have a higher cooling load due to the chimney effect. In some cases, you may want to provide dampers on the returns to pull the air from the best location. Copyright 2003 Unico, Inc.

160 No. 109 / February 2001 Humidification for Unico Heating Systems Unico, Inc. has solicited recommendations from residential size humidifier manufacturers as to their models that would be compatible with the Unico System recognizing the factors listed above. These recommendations are shown in Tables 1 through 3 for the responding manufacturers for the specific applications that are discussed in the following paragraphs. While Unico, Inc. is passing these recommendations on to the installers and users, Unico, Inc. assumes no responsibility for the selections and recommends that the individual humidifier manufacturers be consulted for their detailed installation procedures. It is not intended that this list is complete, as there are some manufacturers that did not respond and some new to the market place that may have applicable equipment. There are also two manufacturer s models that may be applicable to the Unico System that requires further testing as listed in Table 4. Introduction To consider humidification with the Unico System heating system the following factors must be taken into consideration: 1.) Higher operating static pressure. typically, 373 Pa [1.5 inches water column] on the supply side compared to conventional systems at 37 to 125 Pa [0.15 to 0.50 inches of water]. 2.) Small ductwork system. The plenum (main duct) is either 228 or 178 mm [9 or 7-inch] diameter, or mm [6.5 x 6.5-inch] square. 3.) Reduced airflow. Based on cooling capacity, it may be in the range of L/s per kw [20-25 cfm per 1000 Btuh]. For hot water coils, and especially where cooling capacity may not dictate airflow, the airflow may be between L/s per kw [8-30 cfm per 1000 Btuh], depending on the water temperature. 4.) Installed in un-conditioned spaces. The Unico System is often installed in attics, garages, or crawlspaces, which may be subject to freezing temperatures. 5.) High duct velocity. The supply duct velocity ranges between 7-13 m/s [ fpm]. Unconditioned Spaces Free-standing Humidifiers. For systems located in unconditioned spaces, such as attics, unheated garages or basements, the humidification systems which require water feed lines can not be located in the potentially freezing ambient. In these cases the safest choice for a humidifier is one that is self-contained and independent of the heating system. See Table 1 for recommended models. Moisture from a centrally located humidifier does a good job of migrating to all areas of a structure where rooms are kept open enough to communicate with the location of the humidifier. However, locating the self-contained unit immediately below or in the vicinity of the central return air for the Unico System can enhance the distribution of humidified air throughout a building. Conditioned Spaces Where the Unico System is located in conditioned spaces and where there is no danger of freezing of water lines there are additional choices. These are listed in the following paragraphs from highest to lowest recommended. 1.) Heated Pan or Steam Type Humidifiers. One of the more viable choices is the heated pan or steam type humidifier that can be mounted in the supply or return plenum. See Fig. 1 for detail of placement. In such cases the plenum should be insulated sheet metal. Because of the small plenum size and high pressure of the Unico System, the return location would be a better choice. A plenum box can be fabricated to match the end of the Unico System coil module and the humidifier mounted through the side or on the bottom of this box that should be insulated. Table 1. Self-Contained, Independent of the Heating System Manufacturer Model Capacity * Aprilaire Division 350-For Basement Installation [12 gpd] 45 L/day Research Products P.O. Box 1367 Madison, WI Installed through the 45 L/day (800) wall [12 gpd] Nortec Industries, Inc P.O Box 698 Ogdensburg, NY (717) Skuttle Route 10, Box 51 Marietta, OH (800) (1.64 kw) RES Electrode Steam Type 60-BC1, Free standing unit with cabinet 48 L/day [12.8 gpd] 49 L/day [13 gpd] ELC 1.1/8A (120v, 1 phase) 30 L/day [8 gpd] Walton Laboratories ELC 3.1/14A (120v, 1 phase) 49 L/day [13 gpd] 90 Dayton Ave. ELC 2.1/4A ( v, 1 30 L/day Passaic, NJ phase) [8 gpd] (973) ELC 2.1/8A ( v, 1 60 L/day phase) [16 gpd] Electrovap Compact Models *Capacity is the maximum rating in gallons per day (gpd) Copyright 2001 Unico, Inc.

161 Technote 109 Page 2 When mounting through the side, keep the humidifier as low as possible so obstruction of the airflow is minimized and permit the air to flow across the top of the humidifier-evaporating pan. To minimize mineral build-up be sure to use a humidifier that has a flush timer that replaces the water Table 2. Steam Humidifiers Duct Mounted Manufacturer Model Capacity * Honeywell, Inc 49 L/day HE Douglas Drive North [13 gpd] Golden Valley, MN L/day HE 460 (800) , ext.7204 [17 gpd] 49 L/day 60-1 Skuttle [13 gpd] Route 10, Box L/day 60-2 Marietta, OH [17 gpd] (800) Use optional flush timer Autoflo, EWC Controls, Inc. 385 Hwy 33 Englishtown, NJ ESU-14 ESU L/day [14 gpd] 75 L/day [20 gpd] (800) Have built in flush timers *Capacity is the maximum rating in gallons per day (gpd) in the pan periodically. If not built in, it should be available as an optional accessory (e.g. Skuttle). Be sure to follow the manufacturer s instructions for periodic cleaning to remove any mineral build-up. See Table 2 for model listings. 2.) Power Humidifiers. Several manufacturers make a humidifier that mounts on the supply plenum and pulls air into the unit past a wetted pad and discharges the moistened air back into the supply air stream at the same location. These humidifiers depend on the heated air to evaporate the moisture so installation on the return where air is about room temperature would significantly degrade performance. While some manufacturers have indicated using hot water will increase the evaporation rate, other manufacturers that indicate their testing shows that using hot water does very little to boost evaporation rates contest this. Having this information Unico, Inc. is recommending that power humidifiers be installed on the return side only when there is no other viable Table 3. Power Humidifiers Manufacturer Model Capacity * Aprilaire Division 68 C P.O Box A** [18 F] Madison, WI Air Temp (800) Honeywell Inc Douglas Drive North Golden Valley, MN (800) , ext Trion, Inc 101 McNeill Rd Sanford, NC (800) HE 360** G C [18 F] Air Temp 72 C [19 F] Air Temp *Capacity is the maximum rating in gallons per day (gpd) **These models are not recommended for installation on the Unico System supply plenum. option because of the likelihood of capacity reduction. No power humidifier manufacturer had any performance data for normal return air temperatures, such as 21 C [70 F] but capacity was estimated at 50% of the rated performance at 49 C [120 F] air temperature. Since the static pressure in the Unico System supply plenum is typically 373 Pa [1.50 I.W.C.] the power humidifier must withstand this static pressure to operate properly. The first two power humidifiers listed in Table 3 are not recommended for installation on the supply plenum of the Unico System; the manufacturers have indicated these units should not be operated at static pressures over Pa [0.30 to.40 I.W.C.]. The manufacturer of the third power humidifier listed, Trion Model G100, has indicated that their unit will operate satisfactorily at the higher static Table 4. Humidifiers Requiring Testing Manufacturer Model Capacity * Walton Laboratories 90 Dayton Ave. 30 L/day WF-HP-226 Passaic, NJ [8 gpd] (973) Nortec Industries P.O Box 698 Ogdensburg, NY (717) kW RES Electrode Steam Type 48 L/day [12.8 gpd] *Capacity is the maximum rating in gallons per day (gpd) Control Box Plenum Adapter (UPC 61 or 62) Blower Module (MBxxxxx) Heating Module (MHxxxxx) Cooling Module (MCxxxxx) Power Humidifier Plenum Box (Field Fabricated) Return Air Adapter (UPC 59 or 60) Q-Band and Q-Clip Return Air Duct (UPC 4 or 5) Isolation Pads Secondary Drain Pan (UPC 20 or 24) Platform Fig 1. Typical Humidifier placement within the Unico System For 10 foot (3.6 m) Return Duct Do not exceed 100 inches (2.5 m) Return Air Box (UPC 1 or 2) Q-Band and Q-Clip Copyright 2001 Unico, Inc.

162 Technote 109 Page 3 pressure. To mount the humidifier in the supply plenum, it would be necessary to fabricate a rectangular plenum box and mount the humidifier on the side of the plenum box. 3.) Atomizing Humidifiers. We do not recommend this type of humidifier with the Unico System after consulting with several manufacturers. There is a potential for moisture collecting on the inside surfaces of the duct. This is compounded by the high velocity air which would require too great a distance to properly mix. 4.) Bypass Humidifiers. Some humidifiers use a wetted pad and bypass a small amount of supply air through the pad and into the return. The unit normally is mounted on the return duct. These humidifiers are generally not designed for the higher static pressures of the Unico System; therefore, they may leak air. Also, the amount of bypass air is usually about 100 CFM (4.7 L/s) which poses a problem if allowed to bypass for any type of refrigerant system. The Unico System is a low-airflow system and bypassing air can reduce performance and create freeze-up problems for refrigeration systems. For chilled water or hot water systems, a bypass humidifier is acceptable provided it does not leak or degrade performance to an unacceptable level. 5.) Other humidifiers. The survey of humidifier manufacturers has uncovered two manufacturer s models that may have applicability to the Unico System but are not being recommended at this time. Further testing must be undertaken to establish the appropriate installation parameters and performance criteria. These models are shown in Table 4. The Walton Model WF-HP-226 is an atomizing type that should be mounted on the supply side only. Because of the smaller size of the Unico plenum, tubing must be used to connect between the intake and discharge tubes on the humidifier and the plenum. Testing is necessary to determine placement of these tubes, establish length limitations and routing. When using this atomizing type of humidifier it must be recognized that any minerals in the water can be deposited inside the humidifier and also carried into the living space. To prevent this the manufacturer recommends installing an optional De-mineralizing cartridge on the water line. The Nortec D200 has a steam-generating unit that feeds steam through a hose to a nozzle that is mounted in the side or on the bottom of the duct. Testing is necessary to determine nozzle placement and length of hose limitations. Nortec has designed their units (this includes the Model N200 in Table 1) with a disposable cylinder where mineral deposits are collected. This cylinder is replaced after about 2000 hours of operation. Cooling Only Where the Unico System is used only for cooling and a separate central heating system is being used, it is possible to use the Unico System blower to distribute humidified air to the house if certain precautions are taken. Depending on the location of the system (i.e. un-conditioned or conditioned space) the appropriate system can be selected from the tables. However, since the cooling-only air-handling unit would not normally be circulating air during the heating season, it must be energized whenever humidification is required. If the Unico System is located in un-conditioned space, additional precautions are necessary to prevent condensation in the ductwork and continuous air circulation (CAC) should be used. Also recognize that air is flowing through ductwork in an unheated space and air discharging into the conditioned space will be cold. Adding a small amount of heat with a 5kW electric duct heater is one way to overcome this problem. Winter Shut-off Plugs When a Unico System for cooling only is installed in an unconditioned space and used in conjunction with other heating systems, such as in-floor heating, baseboard hydronic or electric ceiling cable or baseboard, and adequate humidification is being provided then it is imperative that the winter shut-off plugs be inserted into the Unico System outlets to prevent condensation inside the duct work (See Fig. 2). All return air openings must also be blocked off. Winter shut-off cap Fig 2. Winter shut-off cap placement Supply outlet Copyright 2001 Unico, Inc.

163 No. 110 / June 1999 Zoning the Unico System General This Tech Note provides instructions for zoning the Unico System for heating or cooling. Do not attempt to zone a system without reading these instructions as there are some limitations for doing so. Unico does not offer zone controls or instructions for wiring. There are many ways to do this and none are standard. Scope A zoned system is designed to independently heat or cool more than one space with one or more units. Zone control is accomplished by modulating the airflow or air temperature flowing into each conditioned space. The best method is dependent on the type of system and level of control required. Quite often in multiple story homes and buildings it is difficult to design a system that will evenly heat and cool each floor. It is normal that the upper floors require less heat in the winter but proportionally more cooling in the summer. Therefore, multiple story buildings are always prime candidates for zoning. Zoning with Multiple Units The easiest and best method for zone control is to provide separate units with their own thermostats. This keeps the design simple and provides redundancy. A good example is a two-story house where there are two units. Each unit conditions each floor. This works well as the sleeping area is usually on the upper floor while the living area is downstairs. There are no limitations for this type of zone control, provided each system has the proper number of outlets for the air flow required for that zone. Zoning with a Single Unit The type of system installed determines how easily the system can be zoned. The easiest to zone is a hydronic system either chilled water or hot water. The most limited is any refrigerant system cooling or heat pump. Systems with an electric duct heater fall in-between. The simplest zoned system uses a separate plenum for each zone. Each plenum should have a two-position (open/close) damper with an end switch. A simple thermostat, located in each zone, will open the damper and close the end switch to start the blower. Additional relays may be required to operate the condenser or boiler/pump. Closing the damper (off cycle) will reduce the total airflow and build up static pressure in the remaining open duct. This could create noise in the remaining open ducts by blowing more air than designed but the increased noise level is not normally objectionable. Refrigerant Systems All refrigerant systems automatically balance themselves to the outdoor and indoor conditions. Reducing the airflow decreases the evaporator temperature and may cause the anti-frost switch to short cycle the condensing unit. If the system is a heat pump, reduced airflow could cause a high-pressure limit nuisance trip. Therefore, do not reduce the airflow below 200 cfm per nominal ton. Likewise, do not bypass the supply air into the return duct, as this is similar to reducing the airflow. If you close off a main trunk you must open another. In other words, make sure that the number of open outlets remains essentially constant. The most common type of system has two zones, where at any given time, the airflow never falls below the minimum. Delivering more than the minimum amount of air is rarely a problem. To illustrate, consider the following examples. Example 1. Consider a nominal 3-ton application with two equal zones. Each zone has a plenum serving each area. The minimum airflow is 600 cfm so the system requires at least 15 full open outlets. Both zones are installed with 10 outlets. Each plenum has a two-position damper that is fully open or partially open (in the closed position). When either zone requires air, the damper in the plenum for that area is fully open. Otherwise, it is partially closed equal to half the airflow (or the equivalent of 5 full outlets). With either zone calling for conditioning the minimum number of outlets is 15 and with both zones open the number of outlets is 20. Notice the number of outlets never drops below 15 when the system is Copyright 1999 Unico, Inc.

164 Technote 110 Page 2 operating. The actual number of outlets in each zone does not have to be equal so long as the equivalent of the minimum number of outlets is always open. Example 2. Consider a nominal 5-ton system with three equal zones with a plenum serving each zone. Only two of the zones need to be controlled by a thermostat, the third zone is common space (between the zones) where the temperature does not need to be closely controlled. The minimum airflow is 1000 cfm with 25 full outlets. Both controlled zones have 13 outlets and the common zone has 12. Use two-position dampers in each plenum. The dampers are set for fully open or fully closed. With either controlled zone calling for conditioned air, the common zone is open and the minimum number of outlets is 25. If both controlled zones require conditioned air, the common zone damper is closed and the number of outlets is 26. A good way to intertwine the duct systems is to use one main plenum where up to three air-handling units blow into. All air handling units should come on simultaneously with individual or 3-stage thermostats to control zone valves for water flow to hydronic coils or the outdoor condensing unit or heat pump section for refrigerant systems. This system will circulate air evenly regardless how many systems are on. You will notice that the refrigerant systems in the examples just shift the air from zone to zone. The system never reduces the air below the minimum. This is called load switching and it does not rely on airflow modulation. Hydronic Systems Hydronic systems are the easiest to zone as there is no possibility of coil freezing or high discharge pressure. The only limitation occurs if you have floor registers. If you have floor registers, you will need to maintain enough air to keep the discharge temperature below 140 F (60 C). These systems do not have any limit to the number of zones. Just be aware that reducing the airflow could create noise in the remaining outlets due to overpressurization of the plenum. If this occurs, use a spring loaded bypass damper to recirculate some of the supply air to the return duct. Electric Duct Heater Systems If electric duct heaters are used the electric elements could cycle on the high temperature limits due to reduced airflow. Refer to the electric heater instructions for the minimum cfm. Single Zone with Multiple Units In some applications, particularly large commercial spaces such as a banquet hall, some sort of capacity reduction is required. This can be accomplished by installing multiple units throughout the room. With multiple units, the duct systems can be separate or intertwined. Separated duct systems will establish zones in the room. This is good design for spaces that incrementally fill up. But if the occupants are interspersed throughout the room you will want to intertwine the duct systems. Copyright 1999 Unico, Inc.

165 No. 113 / March 2004 How to Measure Outlet Airflow Unico now offers the Davis Instruments' TurboMeter. This device is ideal for measuring the airflow in the Unico System. This device makes the Unico System the EASIEST system on the market to check airflow and airflow balance. It is so accurate that you can determine if your duct system is leaky just by comparing the total airflow from all the outlets to the airflow indicated by the motor amperage chart that comes with the blower. Procedure 1. Slide the ON switch to the KNOTS position. This is roughly equal to 100s of feet-per-minute. 2. Place the meter against the outlet with the fan centered over the outlet. 3. Record the KNOTS reading. 4. For all Round Outlets Multiply the KNOTS by 2 to obtain CFM. For the 90 degree Slotted Outlet, multiple the KNOTS reading by 4, then add 4 to obtain CFM. For the Straight Slotted Outlet, multiply the KNOTS reading by 6 to obtain CFM. 5. Use the Unico Service Report Form (Bulletin ) to record your readings and to determine the system total airflow. Examples: Round Outlet with KNOTS reading of 16.3 has 32.6 CFM. (Normal range is between 20 and 40 CFM.) 90 degree Slotted Outlet with 7.1 KNOTS has 32.4 CFM. (Normal range is between 15 and 35 CFM.) Straight Slotted Outlet with 5.6 KNOTS has 33.6 CFM. (Normal range is between 15 and 35 CFM.) TurboMeter is a registered trademark of Davis Instruments, Inc. Note - Specifications, Dimensions subject to change without notice. Copyright 2004 Unico, Inc.

166 Tech Note 113 Page 2 Knots Straight Slotted Outlet Airflow, CFM (L/S) TurboMeter KNOTS-to-Airflow Tables Knots 90º Slotted Outlet Airflow, CFM (L/s) Knots Round Outlet Airflow, CFM (L/s) (9.4) (9.4) (9.4) (9.9) (9.9) (9.9) (10.4) (10.4) (10.4) (10.9) (10.9) (10.9) (11.3) (11.3) (11.3) (11.8) (11.8) (11.8) (12.3) (12.3) (12.3) (12.7) (12.7) (12.7) (13.2) (13.2) (13.2) (13.7) (13.7) (13.7) (14.2) (14.2) (14.2) (14.6) (14.6) (14.6) (15.1) (15.1) (15.1) (15.6) (15.6) (15.6) (16.0) (16.0) (16.0) (16.5) (16.5) (16.5) (17.0) (17.0) (17.0) (17.5) (17.5) (17.5) (17.9) (17.9) (17.9) (18.4) (18.4) (18.4) (18.9) (18.9) (18.9) Note - Specifications, Dimensions subject to change without notice. Copyright 2004 Unico, Inc.

167 No. 115 / July 2004 Air Cleaning / Filtering Devices Introduction When installing the Unico System it should be designed to provide total comfort. To assure that good air quality is delivered to the conditioned space, the inclusion of an air cleaning/filtering device may be desired. This Tech Note describes the variety of such devices that are available and the necessary design criteria to assure continued effective performance. Before proceeding with the selection and design of the air cleaning / filtering device, be sure to read Tech Note 106, Return Duct System Design Requirements. As specified in this Tech Note the one important requirement for the air cleaning/ filtering device is that it should not impose a pressure drop any greater than 0.10 inches of water column (IWC) (25 Pa) based on a total allowable pressure drop for the return duct system of 0.15 IWC (37 Pa), with the return duct being 0.05 IWC (13 Pa). And most important the pressure drop of the filtering device must not increase excessively with time as the filter media loads up with the particulate matter removed from the return air stream. While the Unico System typically includes one central attic return with a flexible return duct and filter grille, there are many situations where fabricated ductwork and/or multiple returns are desired or required. This Tech Note will address those situations as well. Note: In preparation of this Tech Note, Unico has solicited the recommendations from the major manufacturers of residential sized air cleaning devices that would be compatible with the Unico System. The pressure drop limitations and airflow capacities necessary for the various Unico air handlers were defined. The packaged return system that varies with the size of the air handler was as specified in Table 1. The listing of air cleaning devices in this Tech Note may not include all devices available. Some that impose excessively high-pressure drop have necessarily been excluded. Models Return Duct ID inches (mm) Standard Filter Size Inches (mm) Maximum Airflow CFM (l/s) (305) 14 x 20 (356 x 508) 400 (189) (356) 14 x 25 (356 x 635) 600 (283) (457) 14 x 30 (356 x 762) 1000 (472) (508) 20 x 30 (508 x 762) 24 x 30 (610 x 762) 1250 (590) Table 1. Return Duct, Filter Size and Airflow Specifications Filter Types The variety of filter media and choices of basic filtering method provide an array of different pressure drops (see Figure 1.) Electronic Increasing Pressure Drop Disposable Washable Filter Type Fig. 1. Typical Filter Pressure Drop Pleated The Unico packaged return air system is shipped with a disposable filter that is on the low end of the pressure drop curve. Care must be taken when considering any of the higher efficiency type of filters as shown in Figure 1, especially the electrostatic type. In order to use several of the higher efficiency types the filter may have to be oversized as will be discussed later. Manufacturer s Data Electrostatic Most manufacturers of air cleaning devices provide performance data based on ASHRAE Standard 52, Gravimetric and Dust Spot Procedure for Testing Air-Cleaning Devices Used in General Ventilation for Removing Particulate Matter. Typical data might include the resistance, arrestance and efficiency. Of particular interest for considering a device for the Unico System is the resistance which is the initial (clean filter) pressure drop based on an air velocity of 300 ft/min (1.52 m/s). Some manufacturers may show this pressure drop for specific filter models for various flow rates. The important thing to keep in mind is that the pressure drop data is the initial reading for a clean filter. As the filter loads up with dirt the pressure drop will increase. The rate of this increase will vary with the size of the filter, the velocity of the air passing through the filter, and the amount of time the filter is used before cleaning or disposal. The challenge in selecting a Copyright 2004 Unico, Inc.

168 Technote 115 Page 2 compatible filter is to relate the initial resistance rating to the design limit of pressure drop for the Unico System of 0.10 IWC (27 Pa) for initial resistance as measured during the ASHRAE Std. 52 testing at 300 ft/min (1.52 m/s) to allow for the build-up of dirt during operation. This is only a guideline for typical residential applications; if the system were exposed to more extreme environments where there is a likelihood of more adverse dirt exposure or there is less frequent maintenance than recommended by the filter manufacturer, then a lower initial resistance would be dictated. In all cases the filter manufacturer s recommendations should take precedence. Filter Selection To facilitate filter selection for the standard Unico System return air filter grille see Table 2. This table provides the acceptable resistance for five (5) different sizes of filter that fit into the Unico return air filter grille at various design airflows. Since these operate at velocities different from the test value of 300 ft/min (1.52 m/s) the acceptable resistance can be higher for the lower velocities as shown in Table 2. If a selected filter exceeds the acceptable resistance either it should not be used or in some cases a larger filter can be used. This can be done in several ways as follows: 1. Use the next larger filter grille such as the UPC for the UPC or the UPC for the UPC For the UPC there is no larger size to go to. 2. Secure a larger stock filter grille and adapt it to the standard return air ducts or use fabricated return air duct system using ductboard or acoustically lined sheet metal. 3. Use a duct-mounted filter and fabricate a return duct system using ductboard or acoustically lined sheet metal. Air Handler Model Filter Size inches (mm) M x 20 (356 x 508) M x 25 (356 x 635) M x 30 (356 x 762) M x 30 (508 x 762) M x 30 (610 x 762) Design Airflow CFM (l/s) Velocity for Std. Filter Size fpm (m/s) Table 3 provides the necessary filter area (square inches or square cm) for various filter initial resistance ratings. After you have selected your filter, use the initial resistance of the filter to find the required filter area for the airflow of your system in Table 3. The shaded figures are those exceeding the standard filter grille sizes. Electronic Air Cleaners Acceptable Resistance IWC (Pa) 200 (94.4) 102 (0.518).236 (59) 300 (142) 154 (0.782).156 (39) 400 (189) 206 (1.05).117 (29) 500 (236) 257 (1.31).093 (23) 400 (189) 165 (0.838).145 (36) 500 (236) 206 (1.05).117 (29) 600 (283) 247 (1.25).097 (24) 700 (330) 288 (1.46).083 (21) 700 (330) 240 (1.22).100 (25) 800 (378) 274 (1.39).088 (22) 900 (425) 309 (1.57).077 (19) 1000 (472) 343 (1.74).070 (18) 1000 (472) 240 (1.22).100 (25) 1100 (519) 264 (1.34).091 (23) 1200 (566) 288 (1.42).083 (21) 1300 (613) 312 (1.58).077 (19) 1000 (472) 200 (1.02).120 (30) 1100 (519) 220 (1.12).109 (27) 1200 (566) 240 (1.22).100 (25) 1300 (613) 360 (1.32).092 (23) Table 2. Acceptable Resistance for Unico Air Handlers Using Unico Air Filter Grille These are available as ceiling filter grille type or duct mounted type. Where the central single return is being used the Unico filter grille can be replaced with ceiling mounted type Electronic Air Cleaners (e.g. Honeywell F52C and Trion TM2 2000). A return air filter box with connections for the standard flexible return duct must be fabricated to mount the filter grille into. For a multiple Air Handler Model Filter Size inches (mm) M x 20 (356 x 508) M x 25 (356 x 635) M x 30 (356 x 762) M x 30 (508 x 762) 24 x 30 (610 x 762) Design Airflow CFM (l/s) Filter Resistance Rating per ASHRAE Std. 52, IWC ft/min (1.52 m/s) 0.05 (12) 0.07 (17) 0.08 (20) 0.1 (25) 0.12 (30) 0.15 (37) 0.2 (50) Required Filter Area, square inches (square cms) for Resistance 200 (94.4) 76 (490) 90 (581) 96 (619) 108 (697) 118 (761) 132 (852) 152 (981) 300 (142) 114 (735) 135 (871) 144 (929) 161 (1039) 176 (1135) 197 (1271) 227 (1465) 400 (189) 152 (981) 179 (1155) 192 (1239) 215 (1387) 235 (1516) 263 (1697) 303 (1955) 500 (236) 190 (1226) 224 (1445) 240 (1548) 269 (1735) 294 (1897) 329 (2123) 379 (2445) 400 (189) 152 (981) 179 (1155) 192 (1239) 215 (1387) 235 (1516) 263 (1697) 303 (1955) 500 (236) 190 (1226) 224 (1445) 240 (1548) 269 (1735) 294 (1897) 329 (2123) 379 (2445) 600 (283) 228 (1471) 269 (1735) 288 (1858) 322 (2077) 353 (2277) 395 (2548) 455 (2935) 700 (330) 266 (1716) 314 (2026) 336 (2168) 376 (2426) 411 (2652) 460 (2968) 531 (3426) 700 (330) 266 (1716) 314 (2026) 336 (2168) 376 (2426) 411 (2652) 460 (2968) 531 (3426) 800 (378) 304 (1961) 359 (2316) 384 (2477) 430 (2774) 470 (3032) 526 (3394) 606 (3910) 900 (425) 342 (2206) 404 (2606) 432 (2787) 484 (3123) 529 (3413) 592 (3819) 682 (4400) 1000 (472) 380 (2452) 449 (2897) 480 (3097) 537 (3465) 588 (3794) 658 (4245) 758 (4890) 1000 (472) 380 (2452) 449 (2897) 480 (3097) 537 (3465) 588 (3794) 658 (4245) 758 (4890) 1100 (519) 418 (2697) 494 (3185) 528 (3406) 591 (3813) 647 (4171) 724 (4668) 834 (5378) 1200 (566) 456 (2942) 538 (3474) 576 (3716) 645 (4159) 705 (4550) 789 (5092) 909 (5867) 1300 (613) 494 (3187) 583 (3764) 624 (4026) 698 (4505) 764 (4930) 855 (5517) 985 (6356) Table 3. Filter Area for Various Filter Initial Resistance Ratings per ASHRAE Standard 52 Copyright 2004 Unico, Inc.

169 Technote 115 Page 3 return system use one duct mounted Electronic Air Cleaner (EAC) near the air handler if possible. See Table 5 for listing of Electronic Air Cleaners and the pressure drop ratings. Be sure to include the pre-filter and any after filter s (such as carbon media for odor removal) pressure drop. When selecting an EAC for an application, be sure to note the minimum CFM rating that the manufacturer has given for each model. DO NOT SELECT a larger size that has a minimum CFM rating that is greater than the design CFM of the Unico System. The manufacturers have cautioned that operating an EAC at this lower CFM can lead to ozone problems and in some cases the airflow switch (where applicable) will not be activated because of insufficient airflow. Disposable Filters These are the standard filters supplied with Unico filter grilles. These are less efficient filters and the homeowner should replace them frequently depending on system usage. They are more frequently referred to as disposable panel filters. Media typically is fiberglass that can vary in density and thickness (e.g. ½-inch, 1-inch or 2-inch). The thicker and denser filters provide higher arrestance and are more efficient but impose greater pressure drop. The currently available standard panel filters are likely to range from 20-50% arrestance with resistance of.04 to.07 IWC (10 to 18 Pa) and should have acceptable pressure drop for all air handlers at any airflow (see Table 2). Higher efficiency disposable panel filters are available form many manufacturers. When considering these filters, be sure to check Table 2 to see that the resistance is at or below the acceptable level. When resistance values are higher than acceptable, use Table 3 to determine the increase in size that would create an acceptable resistance Manufacturer Disposable Washable Pleated Extended Surface AAF International P.O.Box Louisville, KY X X (888) Air Kontrol, Inc. P.O.Box 597 Batesville, MS X X X (800) Air Guard Industries P.O.Box Louisville, KY X X X (502) Glasfloss Industries P.O.Box X X Dallas, TX Precisionaire, Inc th Ave. North St.Petersburg, FL X X X (800) Purolator Products Air Filtration Co. PO Box 1637 Henderson, X X X NC (800) Research Products Corp PO Box 1467 Madison, WI X (800) Table 4. Manufacturers of Panel Filters by Types rating (based on ASHRAE Standard 52). To illustrate the use of Tables 2 and 3 look at the data for higher efficiency disposable panel filters from AAF International in Table 6. Washable Filters Typically these filters have aluminum mesh or steel media and are marginally acceptable. The resistance may vary from.04 to over.10 IWC (10 to over 25 Pa) with arrestance in the range of 54-75%. Use Table 2 to screen for acceptable models based on resistance and use Table 3 to determine larger filter area necessary when applicable. One major concern in using these filters is getting the homeowner to wash them frequently enough. Pleated Higher Efficiency Filters These filters have an extended surface area through a series of pleats. As the number of pleats increases for each foot of face area the efficiency will increase but so will the pressure drop. These are available from several manufacturers and as with the previous filter categories they should be screened using Table 2 to find ones that have acceptable resistance for the 1-inch thick panel type models to fit into the standard filter grille. Then use Table 3 to determine what larger area is needed when resistance is greater than the acceptable limit. However, the pleated design is also available in thicker (e.g. 4-inch) models that are typically duct mounted, although two manufacturers (Research Products and Trion) have Grill Mount models. See Table 6. All the manufacturers show a minimum airflow rating of 600 CFM for these filters. While they do not indicate the filters will not operate below this CFM, because of the larger size of the filters lower airflow would not give effective filtration and would not be cost effective. Electrostatic Filters These filters are made with varying layers of media. The higher the efficiency the greater the pressure drop. Very few are available that will permit using the standard size filter grille. See Table 7 for a listing of the models having lower resistance. This table shows some models that have higher resistance than is acceptable per Table 2 that would necessitate larger filters (see Table 3). Other Air Purifying Devices In addition to the air filtering devices discussed in the prior sections, there are available in the marketplace other air Purifying devices that are integrated into the air distribution system, typically in the return air ducts. See Table 8. It is recommended that if you are interested in these products that you contact the manufacturer for more complete specifications, limitations and installation detail. Copyright 2004 Unico, Inc.

170 Technote 115 Page 4 Manufacturer Model Type Model No. Duct Opening inches (mm) Pressure Drop IWC (Pa) Airflow CFM (l/s) Matches to Unico Models Min. Airflow CFM (l/s) 0.08 (20) 400 (189) M1218, Return 20 x cell 26(660) x 12.88(327) 400 (189) (31) 600 (283) M2430 Grill F52F 0.08 (20) 800 (378) 20 x 25-2 cell 29.06(738) x 22(559) M (378) 0.10 (25) 1000 (472) Honeywell 16 x 20-2 cell 14.44(367) x 18.25(457) 0.07 (17) 600 (283) M (236) 1985 Douglas Dr. N 0.04 (10) 600 (283) M2430, 16 x 25-2 cell 14.44(367) x 23.25(591) Golden Valley, MN 0.08 (20) 1000 (472) M (236) Duct 0.04 (10) 400 (189) M1218, (800) x cell 18.44(468) x 10.88(276) Mounted 0.08 (20) 600 (283) M (189) F50F 0.04 (10) 600 (283) M2430, 20 x 20-2 cell 18.44(468) x 18.25(457) 0.08 (20) 1000 (472) M (236) 20 x 25-2 cell 18.44(468) x 23.25(591) 0.06 (15) 1000 (472) M (378) All Models have built-in airflow switch (6) 400 (189) M1218, TGM cell 11.13(282) x 20(508) 0.05 (12) 600 (283) M2430, 400 (189) Grille 0.13 (32) 1000 (472) ** M3642 Mount 0.03 (7) 1000 (472) M3642, TGM cell 27(686) x 20(508) 1000 (472) * 0.11 (27) 2000 (944) ** M (5) 600 (283) M2430, SE/HE cell 22.5(572) x 14(356) 0.06 (15) 1000 (472) M3642, 600 (283) Trion, Inc 0.11 (27) 1400 (661) ** M4860 PO Box (5) 600 (283) M2430, 101 McNeill Rd IAQ 1400, 16 x (572) x 13.88(352) 2 cell 0.07 (17) 1000 (472) M3642, 600 (283) Sanford, NC (25) 1400 (661) ** M4860 (800) Duct Mount (4) 600 (283) M2430, IAQ 1400, 20 x 20 19(483) x 17.88(454) (8) 1000 (472) M3642, 600 (283) 2 cell 0.07 (17) 1400 (661) ** M (5) 600 (283) M1218, Trim TX-2 cell 22.5(572) x 13.88(352) 0.05 (12) 1000 (472) M3642, 400 (189) 0.07 (17) 1200 (566) ** M4860 Note: Only the SE Models have built-in Airflow Sensor, optional for all others 0.03 (7) 600 (283) M2430, SST (344) x 18.88(473) 0.07 (17) 1000 (472) M3642, 600 (283) Electro-Air Div (20) 1200 (566) ** M4860 White Rodgers All Models Duct 0.08 (20) 1600 (755) ** M (10) 1000 (472) M3642, SST (344) x 23.63(600) 9797 Reavis Rd (472) * St. Louis, MO Mount & SST (7) 1000 (472) M3642, (314)577-2 cell 17.75(451) x 18.63(473) 0.12 (30) 2000 (944) ** M (472) * 1300 UST 20 x (10) 1000 (472) M3642, 17.75(451) x 18.63(473) 0.12 (30) 2000 (944) ** M (472) * Note: SST Models have built-in Airflow Monitor, for UST Models it is an accessory 0.03 (7) 600 (283) M1218, LakeAir Int'l, Inc All Models Duct M3642 LAD (419) x 20.5(521) M2430, 400 (189) PO Box (17) 1000 (472) Rapids Dr. Mount & 0.07 (17) 1000 (472) M3642, Racine, WI LAD (419) x 24.5(622) 800 (378) 1 cell 0.10 (25) 1400 (661) M4860 (800) Note: Models with suffix are airflow switch equipped * Operate only at this airflow or higher ** Manufacturer s Rating Data which is given for max airflow rating, other pressure drop data is projected form it Table 5. Electronic Air Cleaners (EAC) to match to the Unico System Copyright 2004 Unico, Inc.

171 Technote 115 Page 5 Manufacturer Model Type Model No. Duct Opening inches (mm) Pressure Drop IWC (Pa) Airflow CFM (l/s) Lake Air Int'l 0.02 (5) 600 (283) (406) x 20 (508) PO Box (25) 1000 (472) 1509 Rapids Dr. Duct Mount 0.02 (5) 600 (283) Racine, WI (406) x 25(635) (800) (20) 1000 (472) 0.05 (12) 600 (283) Research Products Space Guard (505) x 21.88(556) 0.09 (22) 1000 (472) PO Box 1467 Duct Mount 0.06 (15) 600 (283) 1015 E. Washington Ave Space Guard (400) x 26.44(672) Madison, WI (25) 1000 (472) (800) Rough-in Box Size 0.05 (12) 600 (283) Grille Mount (540) x 26.25(667) 0.10 (25) 1000 (472) 0.06 (15) 600 (283) Skuttle Mfg. Co. DB (381) x 22(559) 0.11 (27) 800 (378) 101 Margaret St. Duct Mount 0.16 (40) 1000 (472) Marietta, OH (740) (19) 800 (378) DB (457) x 22(559) 0.08 (20) 1000 (472) 0.05 (12) 600 (283) 1200TM 22.63(575) x 13.69(348) 0.10 (25) 800 (378) 0.14 (35) 1000 (472) 0.02 (5) 600 (283) (575) x 17.69(449) 0.06 (15) 800 (378) Duct Mount 0.10 (25) 1000 (472) 0.02 (5) 600 (283) 20 x (486) x 17.69(449) 0.05 (12) 800 (378) Trion Inc PO Box McNeill Rd Sanford, NC (800) Grille Mount 25 x (575) x 17.69(449) Air Bear (645) x 16.38(416) Air Bear (645) x 20.38(518) Table 6. Pleated Higher Efficiency Filters Thicker Designs 0.08 (20) 1000 (472) 0.02 (5) 600 (283) 0.06 (15) 800 (378) 0.10 (25) 1000 (472) 0.05 (12) 600 (283) 0.10 (25) 800 (378) 0.14 (35) 1000 (472) 0.02 (5) 600 (283) 0.06 (15) 800 (378) 0.10 (25) 1000 (472) Manufacturer Air Sponge Filter Co N.W. 35th St. Coral Springs, FL Model Designation Health Smart Filter w/bio Sponge Media Antimicrobial treated Resistance IWC (Pa) Arrestance.09 (23) 93% (800) Note: Adding carbon pad(actasorb) for removing odors adds.05 inches water (13 Pa) Resistance Dust Free, Inc. PO Box 519 Royse City, TX (800) Max. Aire Gold.08 (20) 81% Dust Fighter (25) 84% Dust Star.12 (30) 85% Allergy Gold.12 (30) 90% All have Anti-microbial foam Watchdog 84 *.08 (20) 84% Contractors Choice.08 (20) 84% Remind-Air **.08 (20) NA Newtron Products PO Box Virginia Ave. Cincinnati, OH (800) Anti-bacterial additive included Precisionaire, Inc PO Box 7568 St.Petersburg, FL (201) Glasfloss Ind., Inc. PO Box Dallas, TX (214) Natural Air Anti-microbial.23 (58) # 90% Z-Line MR-8.21 (53) # NA * Sounds alarm when CO is detected. ** Signals (whistle) when filter needs cleaning # Filters exceed Resistance ratings all air handers except 200 CFM (94.4 l/s); larger filters required per Table 3. Table 7. Electrostatic Air Cleaners with Lower Resistance Manufacturer Kleen-Air Co. 269 W.Carmel Dr. Carmel, IN (317) Alpine air of New York 16 High Ridge Rd. Plainview, NY (516) Model Type Ozone Generating Devices Ozone Generating Devices Model Oxy-Gen Model D-200 Living Air Model XL-15 (up to 2500 sq.ft.) (232 sq. m) Living Air Model 880 (up to1000 sq.ft.) (93 sq. m) Elite Environmental Products Second Model 1000 KCS 5216 Chesbro Rd Wind Air (up to 4000 sq.ft) Agoura Hills, CA Purifier (372 sq.m) (818) Table 8. Air Purifying Devices Copyright 2004 Unico, Inc.

172 Electrical and Physical Data Model Number RAND- Phase Frequency (Hz) Voltage (Volts) ELECTRICAL Compressor Fan Motor Locked Full Load Rotor Amperes Amperes (FLA) (LRA) Rated Load Amperes (RLA) Minimum Circuit Ampacity Amperes Fuse or HACR Circuit Breaker Minimum Amperes Maximum Amperes Face Area Sq. Ft. [m 2 ] Outdoor Coil PHYSICAL 018J*Z / / /11 15/15 15/ [0.84] [774] 68 [1928] 135 [61.2] 145 [65.8] 024J*Z / / /14 20/20 20/20 11 [1.02] [897] 76 [2155] 145 [65.8] 155 [70.3] 030J*Z / / /19 25/25 30/ [1.2] [1189] 88 [2495] 160 [72.6] 170 [77.1] 036C*Z / / /14 20/20 20/ [1.6] [1553] 116 [3289] 180 [81.6] 190 [86.2] 036D*Z [1.6] [1553] 116 [3289] 180 [81.6] 190 [86.2] 036J*Z / / /20 25/25 30/ [1.6] [1553] 116 [3289] 180 [81.6] 190 [86.2] 042C*Z / / /17 20/20 25/ [1.6] [1553] 136 [3856] 195 [88.5] 205 [93] 042D*Z [1.6] [1553] 136 [3856] 195 [88.5] 205 [93] 042J*Z / / /26 30/30 40/ [1.6] [1553] 136 [3856] 195 [88.5] 205 [93] 048C*Z / / /17 20/20 25/ [2.14] [1652] 146 [4139] 225 [102.1] 235 [106.6] 048D*Z [2.14] [1652] 146 [4139] 225 [102.1] 235 [106.6] 048J*Z / / /27 35/35 45/ [2.14] [1652] 146 [4139] 225 [102.1] 235 [106.6] 060C*Z / / /21 25/25 35/ [2.14] [1652] 176 [4990] 230 [104.3] 240 [108.9] 060D*Z [2.14] [1652] 176 [4990] 230 [104.3] 240 [108.9] 060J*Z / / /33 40/40 50/ [2.14] [1652] 176 [4990] 230 [104.3] 240 [108.9] Note: Electrical & Physical Data for 048Y*Z & 060Y*Z to be made available at a later date. No. Rows CFM [L/s] R-22 Per Circuit Oz. [g] Net Lbs. [kg] Weight Shipping Lbs. [kg] [ ] Designates Metric Conversions 12 Rheem Manufacturing Company

173 Unit Dimensions AIR DISCHARGE ALLOW 60 [1524 mm] CLEARANCE W L H ACCESS PANEL ALLOW 24 [610 mm] ACCESS CLEARANCE AIR INLETS (LOUVERS) ALLOW 6 [152 mm] MIN. CLEARANCE 3 SIDES ALTERNATE HIGH VOLTAGE CONNECTION (KNOCKOUT) 1 11 /32 [34 mm] SERVICE FITTINGS LOW VOLTAGE CONNECTION 7/80 [22 mm] HIGH VOLTAGE CONNECTION 1 11 /320 [34 mm] Model Number RAND- Height H (Inches) [mm] Length L (Inches) [mm] Width W (Inches) [mm] [482] 33 1 /2 [851] 23 3 /4 [603] [482] 39 [990] 27 5 /8 [702] [482] 43 [1092] 31 1 /2 [800] 036/ [635] 43 [1092] 31 1 /2 [800] 048/ [838] 43 [1092] 31 1 /2 [800] A HIGH PRESSURE CONTROL MANUAL RESET (FIELD INSTALLED ACCESSORY) VAPOR LINE CONNECTION 2 7 /80 [73 mm] DIA. ACCESSORY KNOCKOUTS LIQUID LINE CONNECTION SERVICE ACCESS TO ELECTRICAL & VALVES ALLOW 240 [610 mm] CLEARANCE ONE SIDE [ ] Designates Metric Conversions BEFORE PURCHASING THIS APPLIANCE, READ IMPORTANT ENERGY COST AND EFFICIENCY INFORMATION AVAILABLE FROM YOUR RETAILER. GENERAL TERMS OF LIMITED WARRANTY Rheem will furnish a replacement for any part of this product which fails in normal use and service within the applicable period stated, in accordance with the terms of the limited warranty. For Complete Details of the Limited Warranty, Including Applicable Terms and Conditions, See Your Local Installer or Contact the Manufacturer for a Copy. Condenser Coil leaks caused by factory defects...five (5) Years Compressor A-Series...Eight (8) Years B-Series...Seven (7) Years *Any Other Part...Five (5) Years *This five year limited warranty is applicable only to single-phase products installed in residential applications on or after January 1, Rheem Manufacturing Company 13

174 Condensing Unit Refrigerant Line Size Information System Capacity Model Liquid Line Connection Size (Inch I.D.) [mm] 5/16 [7.93] 5/16 [7.93] 5/16 [7.93] 5/16 [7.93] 5/16 [7.93] 3/8 [9.53] 3/8 [9.53] Line Size (Inch O.D.) [mm] 1/4* [6.35] 5/16 [7.94] 1/4* [6.35] 5/16 [7.94] 1/4* [6.35] 5/16 [7.94] 3/8 [9.53] 5/16* [7.94] 3/8 [9.53] 5/16* [7.94] 3/8 [9.53] 3/8* [9.53] 1/2 [12.7] 3/8* [9.53] 1/2 [12.7] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 50 [15.24] 50 [15.24] 50 [15.24] 24 [7.32] 50 [15.24] 19 [5.79] 50 [15.24] 50 [15.24] 44 [13.41] 46 [14.63] Liquid Line Size Outdoor Unit Above Indoor Coil Total Length Feet [m] 75 [22.86] 34 [10.36] 100 [30.48] Vertical Separation Feet [m] 70 [21.34] 36 [10.97] 33 [10.08] 70 [21.34] 34 [10.36] 75 [22.86] 32 [9.75] 53 [16.15] 61 [18.59] *Standard line size NOTES: ➀ This chart is applicable for condensing units. ➁ Do not exceed 120 feet [36.58 m] maximum vertical separation. ➂ Always use the smallest liquid line possible to minimize system charge. ➃ Chart may be used to size horizontal runs. 42 [12.80] 44 [13.41] 47 [14.33] 40 [12.19] 39 [11.89] 61 [18.59] 72 [21.95] 35 [10.87] 125 [38.10] 48 [14.63] 54 [16.46] 61 [18.59] 11 [3.35] 46 [14.02] 46 [14.02] 70 [21.34] 37 [11.28] 38 [11.58] 150 [45.72] 54 [16.46] 64 [19.51] 16 [4.57] 52 [15.85] 53 [16.15] 39 [11.89] 41 [12.50] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 25 [7.62] 50 [15.24] 23 [7.01] 50 [15.24] 48 [14.63] 50 [15.24] 50 [15.24] 23 [7.01] 23 [7.01] 28 [8.53] 23 [7.01] Liquid Line Size Outdoor Unit Below Indoor Coil Total Length Feet [m] 75 [22.86] 38 [11.58] 100 [30.48] Vertical Separation Feet [m] 8 [2.44] 36 [10.97] 39 [11.89] 9 [2.74] 38 [11.58] 9 [2.74] 40 [12.19] 19 [5.79] 11 [3.35] 30 [9.14] 28 [8.53] 25 [7.62] 32 [9.75] 33 [10.06] 11 [3.35] 3 [.91] 37 [11.28] 125 [38.10] 24 [7.32] 18 [5.49] 11 [3.35] 26 [7.92] 26 [7.92] 3 [.91] 35 [10.67] 34 [10.36] 150 [45.72] 18 [5.49] 8 [2.44] 57 [17.37] 20 [6.10] 19 [5.79] 33 [10.06] 31 [9.45] NOTES: ➀ This chart is applicable for condensing units. ➁ This chart may also be used to size horizontal runs. ➂ Do not exceed vertical separation as indicated on the chart. ➃ Always use the smallest liquid line possible to minimize system charge. ➄ No changes required for flow-check pistons or expansion valve coils. RAND- Unit Suction Line Connection Size Suction Line Run Feet [m] 25' [7.62] 50' [15.24] 100' [30.48] 150' [45.72] Optional Standard Optional Optional Standard Optional Optional Standard Optional Optional Standard Optional Suction Line Length/Size versus Capacity Multiplier /042 3/4" [19.05 mm] I.D. Sweat 7/8" [22.23 mm] I.D. Sweat 5/8" [15.88 mm] O.D. Optional 3/4" [19.05 mm] O.D. Optional 3/4" [19.05 mm] O.D. Standard 7/8" [22.23 mm] O.D. Standard 7/8" [22.23 mm] O.D. Optional 1 1 /8" [28.58 mm] O.D. Optional NOTES: Capacity Multiplier x Rated Capacity = Actual Capacity. Additional compressor oil is not required for runs up to 150 feet [45.72 m]. Oil traps in vertical runs are not required for any height up to 125 feet [38.10 m]. See Liquid Line chart for Vertical Separation Requirements and Limitations. *Actual suction line connection is 7 /8". Adapter to 1 1 /8" [28.58 mm] factory supplied /8" [22.23 mm] I.D. Sweat* 7/8" [22.23 mm] O.D. Optional 1 1 /8" [28.58 mm] O.D. Standard 1 3 /8" [34.93 mm] O.D. Optional [ ] Designates Metric Conversions 14 Rheem Manufacturing Company

175 Bulletin / May 2005 INSTALLATION INSTRUCTIONS FOR THE Unico System ADVANCED CONTROL BOARD Figure 1. Advanced control board in control box General The information on the following pages is to provide the installer the necessary information to properly install the Unico Advanced Control Board (ACB). The ACB control board is available as part of the blower assembly or as part of retrofit kit that includes the motor. Part no. Description M1218A-xx,CB Fan Coil Unit with ACB control, where xx can be AC, HP, CW. MB2430L+CB Blower Module, 2430, with ACB control MB3642L+CB Blower Module, 3642, with ACB control MB4860L+CB Blower Module, 4860, with ACB control A Upgrade Kit, ACB control box with MP Motor, M1218 A Upgrade Kit, ACB control box and 1/2 HP MP Motor, MB2430L A Upgrade Kit, ACB control Box and 1 HP MP Motor, MB3642L and MB4860L Optional Accessories/Replacement Parts A00175-G04 Control Box Assy with ACB (for MB2430L, MB3642L and MB4860L) A00980-G01 Circuit Board, ACB (for all units) A Motor, MP, 1750 RPM, 1/3 hp (for M1218) A Motor, MP, 1750 RPM, 1/2 hp (for MB2430L) A Motor, MP, 1750 RPM, 1 hp (for MB3642L and MB4860L) A00984-G01 Wiring Harness, Power Leads (for US and Canada) A00987-G01 Wiring Adapter Kit, ACB to Single-Speed Motor A00995-G01 Wiring Harness, Power Leads (for Europe) A Fuse, Slow-blow, 2AG, 3A A00057-G03 Transformer, 208/230V-24V, 50VA (for PCB) A Capacitor, 10 µf, 370VAC Scope The Advanced control PCB provides system control for Unico air handlers M1218, MB2430L, MB3624L, and MB4860L. The Control Box Assembly with ACB (P/N: A00175-G04) is also compatible with existing modular air handlers with single-speed motors manufactured after January 2003 (motor is in the airstream). The single-speed motors will require a wire harness adapter (Kit #: A G01), available separately. There is no retrofit kit available for the M1218. Features Congratulations on your purchase on the finest and most versatile fan control on the market. This control board is compatible with the Unico two-speed MP motors and Unico single speed motors (manufactured after January 2003). The control board comes standard with the following features. Multiple configurations. Compatible with refrigerant-cooling (AC) systems; refrigerantheating (heat-pump) systems; chilled water systems, including all UniChiller and UniChillerRC products, hot water systems, electric heat modules, and just about every practical combination of them. Soft-start/Soft-stop. For the ultimate in quiet, the control board will slowly ramp up to speed when it starts and slowly ramp down Copyright 2005 Unico, Inc.

176 Bulletin Page 2 when it shuts off. This feature can be manually enabled or disabled. Ventilation Mode. The board is preconfigured to allow the user to select constant ventilation when the system is not actively heating or cooling. When used with the 2-speed MP motors, the ventilation speed has the further benefit of low operating cost as it uses only 1/4 th of full-speed power. This is nearly the same as a DC motor without the extra costs. Other speed reduction technologies, using variable-speed controls, still use 3/4ths of full power. Simplified Wiring. The control box was developed with the contractor in mind. All wiring terminals are clearly labeled and are designed for point-to-point wiring (one wire per terminal). In addition, we added a feature that allows you to make your terminal connects THEN slip the wire cable into the slotted bushing. Never again, will you have to disconnect and re-wire the board because the cable was not pre-inserted through the bushings. Accessories. The control board provides separate relays and contacts to energize a separate Electronic Air Cleaner (EAC) or UV light. We also provide a relay to energize a humidifier with a separate humidistat input for proper control. We even provide a feature to allow the humidistat to control the fan so that humidity can be added even if the fan is not already on. And, of course, the control is smart enough to sense when the system is trying to cool, so that humidity is not added if in cooling mode. Designed for the Unico Electric Heat Module. When using the Unico Electric Heat Module with the Unico heat pump, we require that third step of electric heaters is not energized at the same time as the electric heat. Previously, we required that a field installed relay or thermostat be installed to prevent this from occurring. The control box provides this feature, saving both time and costs. At the same time, the control board is designed for multiple stage thermostats to gradually turn on the electric heat after the heat pump; thereby, improving the efficiency of the heat pump while maintaining the greatest capacity. Designed for the UniChillerRC. The control is designed to operate the Chiller from the thermostat. And, for multiple thermostat systems, the control boards can communicate, making one the master the others slaves for the best system control available. The board, then, knows whether the chiller is making hot or cold water and turns on the blower as appropriate. Designed for Hot Water Heating systems. The control allows you to select whether the hot water heating is primary, secondary or emergency heat for single or multi-staged systems. Also, a timer function is included to operate the hot water pump when used with potable water combo systems on a periodic basis; this prevents the water from becoming stagnant over time. 2-Speed condenser Compatibility. Two speed condensers with multi-stage thermostats can be used with the board, with an option to operate the first stage at either high or low speed. Quality Design and Manufacture. The board itself is made from high quality electronic parts. The board includes a conformal coating to eliminate problems with humidity, moisture, and dust. It is resistant to high voltage discharges (lightening resistant, not lightening proof which, of course, nothing is!). It is fully certified to UL standards and listed as part of the Unico Blower Module with ETL. Every board is fully tested. ACB Control Box Copyright 2005 Unico, Inc.

177 Bulletin Page 3 Location and Mounting Before installing the PCB, inspect thoroughly for shipping damages. Notify carrier immediately if there is any damage. The control box can be installed in one of two positions on the modular air handler (Figure 2). Chose the position that allows the best access. Plenum Figure 2. Control Box Mounting Locations. Blower Module Control Box Location CAUTION The control box must be screwed to the air handler to provide proper ground for the motor. The large knock-out on the air handler must be removed to allow the motor cable connector to protrude into the air handler space. WIRING WARNING! DISCONNECT ELECTRICAL SUP- PLY BEFORE WIRING UNIT TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK. All electrical wiring must comply with all local codes and ordinances. Use a separate 1 ph- 208/240V-60 Hz power supply with appropriate amp fuse or breaker and wire gauge for the specified amperage. Once the control box is mounted, the motor can be connected from inside the air handler. Remove the appropriate air handler access panel. Connect the 9-pin motor connector to the mating connector on control box. Push firmly; be sure the connector is seated. Table 1. Wiring Configurations Cooling Primary Heat (Optional) Secondary Heat Connect the following using the wiring drawing for your particular system shown in Table 1. 1) Thermostat to the stat terminal block on the PCB 2) Outdoor unit to condenser terminal block on the PCB 3) Air cleaner, humidity system, boiler, valve, or pump to the output terminal block on the PCB 4) Electric heat control module to the electric heat terminal block on the PCB For input power, remove one of the knockouts and install a cable clamp. Connect line power to the black and red power leads using wire nuts. Power leads may also be black and black. Feed wires to the black, red, and green (or black, black, and green) wires in the lower compartment: Ground to green, L1 to red (or black), L2 to the black (or red) (see Figures 3 through 5.) L1, Red (or Black) L2, Black Ground, Green (Optional) Emergency Heat Use Elect. diagram 1 A/C 1 A/C Hot Water Elect. Heat 1,3a,4 A/C Elect. Heat Elect. Heat Hot Water 1,3b,4 Heat Pump Heat Pump 2 Heat Pump Heat Pump Elect. Heat Elect. Heat 2,5 Heat Pump Heat Pump Elect. Heat Hot Water 2,3b,5 Heat Pump Heat Pump Hot Water 2,3b Chiller 7 Chiller Hot water Elect. Heat 7,3a,4 Chiller Elect. Heat Elect. Heat Hot Water 7,3b,4 Rev. Cycle Rev. Cycle 8/9 Rev. Cycle Rev. Cycle Hot Water 8/9,3b Rev. Cycle Rev. Cycle Elect. Heat Elect. Heat 8/9,4 Rev. Cycle Rev. Cycle Elect. Heat Hot Water 8/9,3b,4 IL00398.CVX Figure 3. Power Leads (part no. A00984-G01), included with Control Box. Copyright 2004 Unico, Inc. Copyright 2004 Unico, Inc.

178 Bulletin Page 4 Special Wire Harness for European Countries. For European countries that require CE certification, replace the power leads included with control box (part no. A G01) with the CE wire harness shown in Figure 6 (part no. A00995-G01, sold separately). Figure 4. Location of power leads (Red, Black) and ground (green/yellow). Figure 6. Power Lead Wire Harness for European (CE) Applications, part no A00995-G01 (sold separately). Figure 5. Connect line power to power leads. Use wire nuts. Switches There are a number of function switches on the PCB (refer to Figure 7 for location). The switches have small plastic stem that can easily be moved with your thumb. The description of each switch is listed below: Voltage ( , default = 230) Sets the proper low voltage, depending on the line voltage. If the line voltage is between 220 and 250, move the switch to the 230 setting. If the Figure 7. Control Board Layout Copyright 2005 Unico, Inc.

179 Bulletin Page 5 line voltage is between 190 and 220, then move the switch to the 208 setting. Humidistat Control (ON OFF, default = OFF) Allows a separate humidistat to control the fan operation under certain conditions. The control board has a humidifier relay which provides a set of dry contacts across the HumVlv terminals which is controlled by the presence of a 24 V signal at the HumStat terminals. In the default condition (Humidistat Control=OFF) the relay will only close if the fan is already energized; if the fan is not already energized, the humidity valve switch will not operate. If the Humidistat Control switch is moved to the ON position, the fan will first come on at low speed then humidifier relay will close. In most cases switching the HumStat Ctrl=ON will increase humidifier performance, especially when using a power humidifier in the cold air return system. Potable Water (ON OFF, default=off) For combo systems, where potable water is circulated through the hot water heating coil, it is necessary to ensure that the water is never stagnant in the coil. The switch will activate a timer so that the BPV switch will energize a pump to circulate water once per day for 5 minutes regardless. Winter (ON OFF, default=off) Used to periodically circulate air through the ducts to reduce the chance of moisture build up in the winter months. Fan will run on low speed for 5 minutes each day even if there is no thermostat demand for heat or cool or fan. Ramp (ON OFF, default=on) Allows the blower to ramp up to full speed when starting or stopping. The ramp is 45 seconds and is not adjustable. Ramping the speed enhances the quietness of the system. Moving the switch to the ON position enables this feature. If an electric heater is installed, the electric heater will not come on until the fan reaches full speed. Rev. Valve (B O, default = disabled). By default this switch is disabled unless the reversing valve jumper wire is cut. The board is factory setup for reversing valves that are energized in the cooling mode and require the O signal. If the reversing valve is energized on heating, the heat pump jumper wire (see next section) must be cut and this switch moved to the B position. The UniChillerRC energizes the reversing valve in the heating mode so the switch must be set to B and the heat pump jumper wire must be cut. To prevent the potential of coil frosting for cooling-only systems, be sure the jumper across R and O-b is in place. If not, the AFS may not work properly. This switch along with the O-b input allows the control board to know when the unit is heating or cooling (or if the water is hot or cold) in accordance with the following logic diagram. Table 2. Water Temperature Logic O-b = 1 O-b = 0 Rev.Valve=B HOT COLD Rev.Valve=O COLD HOT Motor Speed (1 2, default=2). The control board is designed for all Unico blowers where the motor is mounted directly to the blower housing with three legs. The control board is compatible with both the single-speed and the two-speed motors. The motor speed switch changes the timing for voltage control for low speed operation. For existing single-speed motors move the switch to the 1 position. For the newer two-speed MP motors operating between 224 and 250V, leave the switch in the 2 position. For two-speed motors operating between 200 and 223V, use the 1 speed setting. The motor speed can be identified by the motor connector. The single-speed motors have a 6-pin connector and the two-speed motors have a 9- pin connector. Chiller (Master Slave, default=master). This switch controls the operation of both the chiller relay (ColdW) and the boiler relay (BPV). If the switch is in the master position, the relays will energize according to Table 4. If the switch is in the slave position, the relays will not energize unless the system thinks the water is the correct Copyright 2004 Unico, Inc. Copyright 2004 Unico, Inc.

180 Bulletin Page 6 temperature. In other words, if the water is hot and the thermostat calls for cooling, the ColdW relay will not energize; however, the fan will still come on which will at least provide ventilation without heating the room when you need cooling. Boiler Priority (Emerg Primary, default = Primary). This switch controls when the boiler and chiller relays are energized. The functional chart is shown in table 3. Refer to Diagram 3 for proper wiring. Table 3. Boiler Priority Switch function chart Boiler Priority=Primary BPV is energized with W or E (call for heat or emergency heat) ColdW is energized with Y (call for cooling) Boiler Priority=Emerg BPV is energized only with E (call for emergency heat) ColdW is energized with Y or W (call for cooling or heating) Note: E, W, W2 always energize the electric heater terminals, regardless of this switch. for cooling at the Y2 terminal the fan speed is high, whereas, at the Y1 terminal the fan speed is low. The jumper forces the fan to run on high during all cooling modes. Therefore, the jumper is in place to allow the installer the ability to use either terminal. For two-stage condensers, this jumper must be removed. R Aqua (accessories block) allows the hot water relay to function without an optional aquastat. If an aquastat is used, this jumper must be removed. Heat Pump Jumper Wire (permanent jumper on board) disables the Reversing Valve switch so that it is permanently in the O position. For systems that have a reversing valve that is energized in heating and requires a B connection, cut the jumper with a wire snips and move the Rev.Valve switch to B. This wire jumper must be cut for proper UniChillerRC operation. Hz (50 60, default=60). This switch controls the timing and voltage function when running in low speed when operated using 50 or 60 Hz power supply. Jumpers There are several jumpers on the PCB that are provided to make the most common wiring applications easier. These must be removed for some applications. The description of each jumper is listed below: R Ob (thermostat block) jumper is required for all cooling-only systems. The board is preconfigured for heat-pump systems that energize the reversing valve in the cooling mode (i.e. require O ). The control senses the signal on the O-b terminal to determine whether it is in cooling or heating mode. Therefore, for cooling-only systems it is necessary to provide this jumper so the control knows it is in the cooling mode. For heat pump systems or UniChillerRC systems, this jumper must be removed. Y2 Y1 (thermostat block) jumper is used for the convenience of the installer when using a single-speed condenser. If the thermostat calls Copyright 2005 Unico, Inc.

181 Bulletin Page 7 Terminal Block Description The following tables describe in detail the function of each terminal on the control board. Table 4. Thermostat Terminal Block Description R Power out. 24V power signal. O-b Reversing valve input from thermostat. Can be either O or B, depending on the requirements of the outdoor unit. For UniChillerRC the selection should be B. G Fan input. Blower will operate at low speed unless there is a call for heat or cool Y2 Cool input. Will energize blower on high and pass a signal to condenser Y2 terminal. Y1 Cool input. Will energize blower on low and pass a signal to condenser Y1 terminal. W Heat input. Blower will operate at high speed, electric heater S1 terminal will be energized, and water relays will energize in accordance to Tables 3 and 4. W2 Heat input (second stage). Electric heater S2 terminal will be energized. W signal must be present to energize the fan. W3 Heat input (third stage). Electric heater S3 terminal will be energized unless it is a heat pump (i.e. signal present at Y2 or Y1). W signal must be present to energize fan. E Emergency heat input. Will energize blower on high, send a signal to electric duct heater E terminal and energize the water relays per Tables 3 and 4. C Common. Used to power the thermostat, if required. Note: Factory ships with jumper across Y2 and Y1, and a jumper across R and O-b. The Y2-Y1 jumper must be removed for two-speed condensers. The jumper is only a convenience so that either terminal may be used for single-speed condensers. The R-Ob jumper must be removed for heat pump or UniChillerRC systems. The Rev.Valve switch must be set properly. Table 5. Condenser Terminal Block Description R Power out. 24V power signal. AFS- Terminals to connect the anti-frost switch located on AFS the coil. If the AFS is closed, the control will allow the condenser terminals to be energized. If the AFS switch opens, the condensers will stop although the indoor blower will continue to operate. The AFS will not affect operation of the condensers if in the heating mode per Table 3. The AFS switch will open at 34 F±3 F (1 C±1.6 C) and open at 60 F±5 F (15.5 C±2.8 C). Y2 Cool output. Will energize the second-stage of a twostage condenser. Y1 Cool output. Will energize single-speed condenser or the first-stage of a two-stage condenser. D Defrost input. Will send a signal to electric heater defrost terminal. O-b Reversing valve output. Can be either O or B, depending on the requirements of the outdoor unit. The UniChillerRC uses B. C Common. Used to power the relays and controls in the condenser. Table 6. Accessories Terminal Block Description R Power out. 24V power signal. Aqua Aquastat input. Allows the option of using an aquastat to reduce the time it takes for the air to become hot when heating. The fan will not energize to high speed unless this terminal senses a signal (when the aquastat is satisfied). HumStat Humidi-Stat input. If humidistat is installed across these two terminals, the HumVlv contacts will close whenever the humidistat calls for humidity and the fan is on. HumVlv Dry contact (unfused), rated for 3 amp, 120 VAC. To be used to energize the humidifier. Contacts will close whenever there the HumStat signal is present and the fan is on (If the humidifier switch is in the ON position, the fan to come on low speed if not already on). EAC Dry contact (unfused), rated for 3 amp, 120 VAC. Used to energize an electronic air cleaner or UV-light option. Contacts close when fan is on high or low speed. BVP Dry contact (unfused), rated for 5 amp, 250 VAC. Used to energize either a boiler, valve, or pump. Contacts will close whenever there is a call for hot water heat (see switches section for more information). ColdW Dry contact (unfused), rated for 5 amp, 250 VAC. Used to energize a chiller, valve, or pump. Contacts will close whenever there is a call for chilled water cooling or UniChillerRC heating (see switches section for more information). Note: Factory ships with jumper across R and Aqua. This jumper must be removed if an aquastat is used. Table 7. Electric Heater Terminal Block Description R Power out. 24V power signal. Fan Fan proving output, connected through a relay directly to G on the thermostat block. Once the motor reaches full speed, the relay closes sending a 24V signal to the electric heater to allow the heating elements to energize. The Unico Electric Heater will not function unless this signal is present. D Defrost input, direct connection to D on the condenser block. Will send a signal to electric heater defrost terminal. E Emergency heat output, direct connection to E on the thermostat block. Will energize the electric heater elements. S1 Heat output, direct connection to W/W1 on the thermostat block. Blower will operate at high speed, electric heater S1 terminal will be energized, and water relays will energize in accordance to Tables 2 and 3. S2 Heat input (second stage), direct connection to W2 on the thermostat block. Electric heater S2 terminal will be energized. The electric heater requires that the S1 signal is present in order to energize second stage electric heat. The electric heater requires that the S1 signal is present in order to energize second stage electric heat. S3 Heat input (third stage), connected through a NC-relay directly to W3 on the terminal block. Relay is energized and contacts opened whenever Y2 or Y1 is energized. This prevents the third stage of electric heating elements from energizing when the heat pump is operating. The electric heater requires that the S1 signal is present in order to energize third stage electric heat. C Common. Used to power the relays in the electric heater. Copyright 2004 Unico, Inc. Copyright 2004 Unico, Inc.

182 Bulletin Page 8 Description of LEDs (light emitting diodes) Table 8. LED Chart LED Power (green) Heat (red) Fan (red) PCBctl (red) Condition Indication Flashing Board is functioning properly. If not flashing, remove and reapply power to air handler. Solid 24V is present, but unit not functioning properly. Off System is not in heating mode (or W and Y are energized at the same time, which is a wiring problem). Solid System is in the heating mode. Off Fan is off or changing speeds between high and low or from a complete stop. Solid Off Solid Fan is at constant speed, either high or low. PCB is not controlling fan or BVP relay independent of thermostat. PCB is controlling fan or BVP relay independently of the thermostat (i.e. not signal at G, W, or Y). If fan is on, indicates humidistat or winter mode is forcing the fan to energize. If fan is not on, indicates BVP relay is closed in response to the Potable Water timer. Is this a new control box added to an older one-speed air handler? Refer to Diagram 12. Is the original variable-speed control connected as shown. If so, be sure the variable speed control is adjusted to achieve the desired low speed (turn clockwise). Fan runs without demand from thermostat Is PCBctl LED lit? This is normal. The fan is running because of a built-in turn-off delay, or the winter switch is activated, or Humidity always is selected and the humidistat is demanding water. Is Power LED flashing? If not, the processor is stopped executing, remove and reapply power. Heat pump compressor runs in heat mode but does not run for air conditioning. AFS (automatic frost switch) input is open. The AFS terminals must be connected to a frost switch. Heat pump compressor runs but is cooling when it should be heating or heating when it should be cooling. Is the Reversing Valve switch set properly? (If the outdoor reversing valve requires 24vac for heating, then the Reversing Valve switch should be switched to B and the jumper wire must be cut. 3rd stage electric heat (S3) does not energize Is the thermostat demanding heat pump operation? This is normal. The third stage is disabled during heat pump operation. Fan does not run TROUBLE SHOOTING Power LED off? PCB is not receiving power. Check connection to line (mains) Power LED on but not flashing? PCB has power but processor is not executing. Disconnect power, wait 10 seconds, reconnect power. Is the thermostat energizing G, W or Y? Check if 24Vac exists from C to G, W, Y1, Y2, or E. If no voltage exists on any of these, check connection between PCB and the thermostat. Check connection at the thermostat or replace the thermostat. If 24vAc does exist on G, W, or Y check the connection between the control box and the motor. Disconnect and reseat the motor connector. Check the connection of the motor capacitor. Check that the motor is free to turn. Fans runs high speed but not low speed Note: For low-speed operation, the thermostat must energize G but not W, Y2, or E. Check that this is the case. Copyright 2005 Unico, Inc.

183 Bulletin Page 9 DIAGRAM 1. A/C ONLY Be certain that the jumper is in place between R and O-b. DIAGRAM 2. HEAT PUMP ONLY Remove the jumper between R and O-b on the thermostat block. If the reversing valve is energized in the heating mode (such as UniChillerRC), then cut the heat pump jumper wire with a wire snips and be sure that the Reversing Valve switch is in the B position and connect the B thermostat terminal to the O-b terminal on the board. If the heat pump reversing valve requires power during cooling (i.e. requires the O signal), it is not necessary to cut the reversing valve jumper wire. However, if the wire is cut, then move the switch to the O position and connect the O thermostat terminal to the O-b terminal on the control board. Note most heat pumps use O ; the UniChillerRC uses B. Copyright 2005 Unico, Inc.

184 Bulletin Page 10 DIAGRAM 3a. AC or Chilled Water with Primary Hot Water Heating option (boiler operation) Thermostat R O-b G Y W R O-b G Y2 Y1 W W2 W3 Emerg Primary Boiler Priority AC with Hot Water Heating, AC with Electric Heater and Hot Water heating (electric heater is for emergency) Mtr Speed Ramp 1 2 On Off Jumper Wire, B O Emerg Primary Cut if Rev. Valveuses B Rev Valve Boiler Priority R Aqua Humstat Humvlv EAC BVP Cold Max. 5 A, 250 VAC (must be fused) Boiler X X For proper boiler operation, select the appropriate Boiler Priority as shown. If an aquastat is used, refer to Diagram 8. In boiler operation, the Unico control board provides a set of dry contacts to turn the boiler on. The boiler is required to turn on any pumps or valves in the system. Please note that the BVP relay is rated for 5 amps at 250 VAC. For complete protection, be sure wiring to relay is externally fused. DIAGRAM 3b. AC, Chilled Water, or Heat Pump with Emergency Hot Water Heating option DIAGRAM 3c. Hot Water Heating option (pump or valve operation) Thermostat R O-b G Y W E Mtr Speed 1 2 B O Rev Valve Ramp On Off Jumper Emerg Primary Boiler Priority Wire, Cut if Rev. Val ve usesb R O-b G Y2 Y1 W W2 W3 E C R Aqua Humstat Humvlv EAC BVP Cold Emerg Primary Boiler Priority Heat pump with Hot Water heating, AC with UniChillerRC and Hot Water heating (no electric heaters), AC with Electric Heater and Hot Water heating (Hot water is for emergency) Max. 5 A, 250 VAC (must be fused) Pump or Valve X X + - Power If desired, the valve can have an end switch to power on the pump or boiler separately. If an aquastat is used, refer to Diagram 8. Copyright 2005 Unico, Inc.

185 Bulletin Page 11 DIAGRAM 4. AC with ELECTRIC HEAT Refer to Diagram 1 to wire outdoor condenser unit. DIAGRAM 5. Heat Pump with ELECTRIC HEAT Refer to Diagram 2 to wire outdoor heat pump and for instructions for setting the reversing valve O-b switch. For 2 or 3-stage heating, if hot water coil is used for emergency heat, then do not connect the thermostat E to W and refer to Diagram 3b. Copyright 2005 Unico, Inc.

186 Bulletin Page 12 DIAGRAM 6. Emergency-Only Electric Heater DIAGRAM 7. UniChiller (cooling-only) or Generic Chilled-Water System Copyright 2005 Unico, Inc.

187 Bulletin Page 13 DIAGRAM 8. Single UniChillerRC with One Air Handler (Intermittent Pump) This schematic allows the thermostat to turn on the pump whenever there is a call for heat or cool. The blower will operate immediately while the UniChiller attempts to maintain the water set point temperature. This is the most efficient mode although it may take a few minutes for the water to reach its setpoint. To eliminate this delay and maximize the capacity of the system, run the pump constantly as shown Diagram 9. (1) Remove the jumper between R and O-b on the thermostat terminals. (2) Cut the reversing valve jumper wire to enable the O-b Reversing Valve switch, then move Reversing Valve switch to the B position. (3) Disconnect transformer inside of UniChiller. Move Chiller switch to Master position. The Master position allows the thermostat to control the UniChiller operation. Copyright 2005 Unico, Inc.

188 Bulletin Page 14 DIAGRAM 9. One or more UniChillerRCs with One or more Air Handlers (Constant Pump) In this configuration, the UniChillerRC pump is energized whenever power is applied to the UniChiller (i.e. the pump will run constantly). The diagram also shows optional slaved units. The slaved air handler will not close the ColdW contacts if the water is the wrong temperature. For example, if the slave thermostat calls for cooling and the UniChiller is set for hot water ( B is energized), then the ColdW relay will not close and only the fan will come on to provide air circulation. Set the Boiler Priority on the slaved unit to Emergency ; otherwise the BVP relay will close instead of the ColdW relay. The BVP relay will still be energized if the thermostat E terminal is energized. Similar to the one-chiller, one-ahu design (diagram No. 8), remove the jumper between R and O-b of the thermostat terminals, cut the reversing valve jumper wire to enable the O-b reversing valve switch. Move Reversing Valve switch to the B position. Disconnect transformer inside of UniChiller. The Master chiller must have its Chiller switch moved to the Master position; all slaved units must have the chiller switch move to the Slaved position. Copyright 2005 Unico, Inc.

189 Bulletin Page 15 DIAGRAM 10. HUMIDITY SYSTEM Hum. Ctrl ON OFF Hum. Ctrl ON OFF Pot. Water ON OFF Pot. Water ON OFF S3 C R Aqua Humstat Humvlv EAC BVP Cold R Aqua Humstat Humvlv EAC BVP ColdW HumidiStat X X R C Humidifier (Max. 3 amp, 120 VAC) + - Power HumidiStat X X + Humidifier - 24 V (Max. 3 amp) (for line voltage power humidifier or humidifier valve) (for 24 V power humidifier or humidifier valve) Set Humidity Control switch to proper position. The ON position will energize the fan low speed in response to a call for humidity from the humidistat unless the fan is already in high. Also, the Humidity Valve relay will close and turn on the humidifier. If the switch is in the OFF position, then the humidity valve relay will only close if the fan is already running on high or low. DIAGRAM 11. Electronic Air Cleaner (EAC), Recovery Ventilator (ERV or HRV), or UV light connection Hum. Ctrl ON OFF Hum. Ctrl ON OFF Pot. Water ON OFF Pot. Water ON OFF S3 C R Aqua Humstat Humvlv EAC BVP Cold R Aqua Humstat Humvlv EAC BVP ColdW + - Power R C Electronic Air Cleaner or UV Light (Max. 3 amp, 120 VAC) (for line voltage EAC or UV light) V Electronic Air Cleaner or UV Light (Max. 3 amp) (for 24 V power EAC or UV light) The EAC relay will close whenever the fan is energized. Copyright 2005 Unico, Inc.

190 Bulletin Page 16 DIAGRAM 12. Connecting to Unico System Single-Speed Motors Wire Harness Adapter Kit for Single Speed Motors (Kit no. A00987-G01) Main Wire Harness, Single-Speed Motor/PCB (Part no. A00982-G01) R O-b G Y2 Y1 W W2 W3 E C R AFS D Y2 Y1 O-b C R= 24 Vac C= Common Single Speed Motor 6-pin plug 9-pin plug 230V 240V Power PRP 208V Transformer connection RED Motor Connection 240V (Ora) 208V (Red) Chiller Master Slave 60Hz (Blu) (Yel) 50Hz LED s Power Heat Fan PCB ctl 24V Transformer connection Mtr Speed 1 2 B O Rev Valve Ramp On Off Emerg Primary Boiler Priority On Winter Off Hum. Ctrl On Off Pot Water On Off Jumper Wire, Cut if Rev. Valve uses B Connect Ground inside of Control Box Spare Fuse R Fan Common (Blk) D E S1 S2 S3 C R 3AmpFuse Aqua HUMSTAT HUMVLV EAC BVP Cold Speed Controller (SC) (from existing control box) Off Max Speed Controller Wire Assy, M/F Quick Connect (Part no. A ) Speed Controller Wire Assy, M/M Quick Connect (Part no. A ) R O-b G Y2 Y1 W W2 W3 E C R AFS D Y2 Y1 O-b C R= 24 Vac C= Common Mn 240V Power Chiller Master Slave On Winter Off Mound SC in new control box and connect wires as shown. 230V 208V PRP Transformer connection RED Motor Connection 240V (Ora) 208V (Red) Common (Blk) 60Hz (Blu) (Yel) LED s Power Heat Fan PCB ctl 50Hz 24V Transformer connection 3AmpFuse Mtr Speed 1 2 Ramp On Off B O Emerg Primary Rev Valve Boiler Priority Hum. Ctrl On Off Pot Water On Off Jumper Wire, CutifRev. Valve uses B Be sure to move the Motor Speed Switch to the 1' position. Spare Fuse R Fan D E S1 S2 S3 C R Aqua HUMSTAT HUMVLV EAC BVP Cold The Advanced Control Board may be used with all Unico existing single speed blower motors that are mounted directly to the blower housing (all blowers built after January 2003). The variable speed controller used for continuous ventilation speed in the existing control box may be installed into the Advanced Control Box to keep this feature. Otherwise, without using the variable speed controller, the fan will only operate at high speed. (Note To obtain the highest efficiency in continuous ventilation mode, we recommend replacing the single speed motor with the Unico two-speed MP motor.) The single-speed motor requires the use of an adapter kit (Kit number A00987-G01) as shown above. Be sure to move the Motor Speed Switch to the 1 position and to attach the adapter harness ground wire inside the control box. Connect ground wire to control box with sheet metal screw. Copyright 2005 Unico, Inc.

191 Unico System with Heat and Air Conditioning using the HFC201 Taco Control THERMOSTAT C R W Y G TO PUMP RELAY C R W Y G T T T T WATER COIL FREEZE PR THERMOSTAT Aquastats HAFC201 HYDRO AIR FAN CONTROL DRY CONTACTS 5 AMP 1/6 HP RATED PUMP BOILER AIR HANDLER X X X X C R Y G G Volt Connection Condenser Connections Inside Unico with Heat and A/C

192 C R W Y G THERMOSTAT TO PUMP RELAY C R W Y G T T T T WATER COIL FREEZE PR THERMOSTAT Aquastats HAFC201 HYDRO AIR FAN CONTROL DRY CONTACTS 5 AMP 1/6 HP RATED PUMP BOILER AIR HANDLER X X X X C R Y G G UNLATCHING RELAY Unico Control Box BLU RED YEL RED BK YEL TO FUSED 230V DISCONNECT NOT OVER 15 AMP FUSE 4 6 LO RELAY 3 YEL TO OUTDOOR CONDENSING UNIT GRD. LEAD TO MOTOR BASE BK BRN BRN BRN RED BK 4 RED 6 HI RELAY 3 BLU BLU BLU 24V YEL BRN ANTI-FROST CONTROL YEL V 230V L1 RED BLU COMMON OR TRANSFORMER 1 3 ANTI-FROST CONTROL BYPASS RELAY L2 EQUIPMENT GROUND BK

193 To Condenser 24 Volt Connections T8401C1015 R W G Y C Check for wire size using electrical table in Unico Book ** Low Voltage Terminal Block Inside Cabinet 240 Volt connection to the Air Handler ** 240 Volts