Heat Controller SDAH 24, SDAH 48, SDAH 36 Installation Instructions Manual

INSTALLATION

INSTRUCTIONS

SMALL DUCT HIGH VELOCITY:

SDAH 24 / 36 / 48 Fan-Coil Units

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

Bulletin 100-155 — Installation Manual

GENERAL

The information on the following pages is to help the
installer save time by provide the best possible installa­tion and ensure continuous trouble-free operation.

SCOPE

These instructions apply to the Heat Controller SDAH
Series. Installation instructions for the air distribution
system are covered in Bulletin 100-145. Before begin­ning any installation a detailed system layout must be
done in accordance with the System Sizing and Layout

Procedure, Bulletin 100-255 and the Component Layout
Instructions, Bulletin 100-250.

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.

HEAT CONTROLLER

INSTALLATION MANUAL

FOR

SDAH SERIES

TABLE OF CONTENTS

INTRODUCTION ................................................................... 1

OPTIONS ............................................................................. 2

UNPACKING ......................................................................... 2

LOCATION ............................................................................ 2

UNIT ASSEMBLY .................................................................. 3

Anti-Frost Switch Wires .................................................. 3

Fastening Modules Together .......................................... 3

Horizontal Installation ..................................................... 3

Control Box ..................................................................... 4

Secondary Drain Pan ..................................................... 4

MOUNTING ........................................................................... 4

Horizontal Platform Mounting ......................................... 4

Horizontal Suspended Mounting .................................... 5

DUCT CONNECTIONS ........................................................ 5

Supply Plenum ............................................................... 5

Return Duct .................................................................... 6

Multiple Returns .............................................................. 7

PIPING .................................................................................. 7

Condensate Lines .......................................................... 7

Refrigerant Lines ............................................................ 7

Water Connections ......................................................... 9

Coil Cleaning ................................................................. 10

WIRING ............................................................................... 10

Ventilation Speed Mode ............................................... 10

STARTUP ........................................................................... 10

Sequence of Operation ................................................ 10

Checking Airflow ........................................................... 11

How To Measure Air Flow ............................................. 12

How to Measure Static Pressure ................................... 12

Charging the System .................................................... 13

Low Ambient Control Kit ............................................... 13

R-410A Refrigerant ............................................................. 13

Maintenance ...................................................................... 14

Module Configuration Illustrations ........................................ 15

Blower Performance ............................................................. 15

Specifications ...................................................................... 16

PART NUMBERS

This manual does not always include the latest revision
letter when referring to SD part numbers. Refer to the
latest Price List and Spec Sheets for the current SD revi­sion letter. For example, in SD-00x the ‘x’ indicates the
latest revision.

INTRODUCTION

Heat Controller offers 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

© Copyright 2010 Heat Controller, Inc.

Bulletin 100-155 — Page 2

series of 2-inch or 2 ½ 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.

The SDAH Series consist of a motor, blower wheel,
housing, controls, and an option of either a heat pump or
chilled water coil. For additional options, the SDAH
series features a latching mechanism for easy installation
of a Hot Water Coil module and/or Horizontal Return
Air Module. This series of air handlers must be installed
in the horizontal flow position to allow for proper drai­nage (See Fig. 1).

All insulated modules feature closed-cell insulation for
improved sound attenuation. There is no exposed fiber­glass insulation.

SDAH module is available in three sizes: 24, 36, and 48.
The SDAH24 is sized for 1.5-2.0 tons, SDAH36 is sized
for2.5- 3 ton, and the SDAH48 is sized for a 3.5-4 tons.

The coils can be arranged to provide only the options
needed as shown in Figure 1 (with details on page 14).
Heating-only systems require the blower with a heat
pump coil, and a hot water coil. Cooling-only systems
include the blower with the heat pump coil used for
cooling. For heating and cooling use the refrigerant coil
with the hot water coil module or electric furnace.

Heat Controller blowers feature direct drive motors that
are located in the air stream. Each blower wheel is ba­lanced to Heat Controller 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 fastened 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 furnace, hot water coil module,
and a horizontal return air module. Please refer to the
latest Heat Controller Catalog for information on these
and other options.

UNPACKING

Open each carton and 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.

LOCATION

Design the system layout to minimize the number of
plenum elbows and fittings while keeping the supply
duct runs as short as possible. (See Bulletin 100-250,
Component Duct Layout Design). Provide minimum
clearance on both sides for servicing the unit as shown in
Fig. 2.

If installing the unit in an attic, avoid placing the unit
above a bed. The ideal location is above a central hall, a
closet, a bathroom, or any normally unoccupied space.

The unit can also be installed in a closet, crawlspace, or
basement. If the local codes allow, the unit may be 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 attic installation). The section on Return Air
Ducts in the manual provides more details.

Table 1. Return Air Box Opening

Models

24 SD-01-24

36 SD-01-36

48 SD-01-48

Return Air Box

Part No.

Size of opening

inches (mm)

3

× 25 ½ (365 × 648)

14

8

3

1

× 30

14

8

2

3

8

× 30

1

2

24

(365 × 775)

(619 × 775)

All Heat Controller products are inspected prior to
shipping and are carefully packaged in individual car­tons. Inspect all cartons prior to unpacking. Notify car­rier of any damage.

Heating or Cooling w/ Heat Pump Coil

Horizontal
Flow

Figure 1. Basic Module Arrangement (refer to detail figures shown on Page 15)

© Copyright 2010 Heat Controller, Inc.

Heating or Cooling w/ Chilled Water Coil Only

Heat Pump C oil w/ Hot Water Coi

IL00010E.cvx

Bulletin 100-155 — Page 3

A

UNIT ASSEMBLY

The units should be assembled horizontally. Refer to
Fig. 1 for your particular flow arrangement. If you use a
refrigerant coil, the anti-frost switch wires must be
routed to the control box during installation.

Anti-Frost Switch Wires

Remove the coil access panel and unravel the anti-frost
switch wires. Feed the wires through the bushing in the
motor partition panel and connect to the condenser ter­minal block on the SIB.

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 2. Minimum Clearances

All SDAH modules except are designed to fit through a
14-inch (356 mm) opening, typical of a joist spaced at
16-inch (406 mm) center distance. 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 module
is listed in Table 1. If the joists or studs are less than 16­inches (406-mm) center-to-center or running the wrong
direction it will be necessary to cut and header the joists.

Blower
Module

Control
Box

Plenum

dapter

(SD-61-xx)

Isolation
Pads

Secondary
Drain Pan
(SD-20x or 24x)

Platform

Figure 3. Typical Horizontal Attic Installation

(SDAHxx)

HP or CWC
(SDAHxxB)

or

(SDAHxxC)

Heating
Module
(SDCMxxH)

Figure 4. Module Flange Connection

All systems are to be installed in the horizontal configu­ration, with the air going from right to left when looking
at the connections (as shown in figure 1).

ReturnAir Adapter
(SD-104-xx)

Band (supplied with return air box)

Typical 10 foot (3.6 m) Return Duct

Use at least one 90° bend.

Return Air Box
(SD-01-xx)

Horizontal Installation

Return Air Duct
(SD-04-xx)

Band

IL00009.CVS

IL00039D.CVS

© Copyright 2010 Heat Controller, Inc.

Bulletin 100-155 — Page 4

Control Box

The control box is shipped with all SDAH models. 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. 5. Feed the wires from the anti-frost switch
through the hole and bushing nearest the side of the unit
and connect the leads to the AFS terminals on the SIB
(System Interface Board) condenser terminal strip. 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.)

Figure 5. 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.

Table 2. Secondary Drain Pan Dimensions, inches (mm)

Unit

Part No.

Size

24 SD-20B

36 SD-27B

SDAH SDAH + Hot Water Coil

Dimensions

inches (mm)

29 × 31.5†

(737 × 800)

34 × 31.5†

(864 × 800)

Part No.

SD-20C

SD-27C

Dimensions

inches (mm)

29 × 43.75†

(737 × 1111)

34 × 43.75†

(864 × 1111)

Like the modules, all the secondary drain pans except
SD-24C 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.

Horizontal Platform Mounting

It is easiest to mount the unit on a platform but care must
be taken to assure proper drain line pitch (see Table 3).

Rafter, Joist
or Floor

B

*

A

IL00036a.CNV

Figure 6. 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)

The platform size must allow for the number of modules
being used. For dimensions for minimum platform size
see Fig. 6.

Unit 24 36 48 24 36 48

A 25 (635) 30 (762) 38 (965) 25 (635) 30 (762) 38 (965)

B 26 (660) 38 (965)

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.

2 × 4 2 × 6 2 × 8 2 × 10

18 (5) 26 (8) 34 (10) 42 (13)

SDAH SDAH + Hot Water Coil

48

SD-24B

† NOTE — The drain fitting extends 7/8 inch (22 mm) beyond this dimension.

© Copyright 2010 Heat Controller, Inc.

42 × 31.5†

(1067 × 800)

SD-24C

42 × 43.75†

(1067 × 1111)

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. 7.
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 a
slight pitch towards the drain end.

HOOK

RAFTER

CHAIN

Bulletin 100-155 — Page 5

Figure 8. Round Supply Plenum Adapter Dimensions

Measure the motor amperage and use this to ensure the
200-250 CFM per nominal ton (27-34 L/s per nominal
kW) has been achieved. If elevated sound levels are 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.

UNIT

SECONDARY
DRAIN PAN

ANGLE IRON

Figure 7. Typical Suspended Mounting

IL00038C.CVN

DUCT CONNECTIONS

Supply Plenum

Heat Controller has a complete line of round plenum
adapters available as shown in figures 8. 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. 9. Sheet metal screws for instal­ling both are provided with the blower.

The restrictor plate is used to set the system airflow (see
Fig. 10). 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 200-250
CFM per nominal ton (27-34 L/s per nominal kW).

Note: Do not use restrictor plate to adjust
plenum static pressure. Adjust the restrictor
to the proper amperage. This will assure
proper airflow.

Attach the plenum to the adapter by inserting it over the
supply adapter. If using sheet metal duct, use three (3) or
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.

Blower
Module

Restrictor
Plate

Plenum Adapter

Plenum

Insulation Wrap

Figure 9. Supply Plenum Adapter Installation

IL00308.CVX

© Copyright 2010 Heat Controller, Inc.