Heat Controller Small Duct, High Velocity Quick Start Manual

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INSTALLATION

INSTRUCTIONS

SMALL DUCT HIGH VELOCITY:

Duct Layout

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

Bulletin 100-135 / August 2010

Installation Guide

This instruction is a summary of the basic rules and applies to most applications.

Duct Layout

Outlets

 7 two inch outlets Per Ton / 5 two and a half inch outlets Per Ton (3.5 kW). For refrigerant cooling applications the

airflow must be between 200 and 250 CFM per nominal ton [27 to 33 L/s per nominal cooling kW]. For hot water or chilled water systems, refer to performance charts for determine the required airflow. The allowable airflow range per 2 inch outlet is 20 to 40 CFM [9.4 and 19 L/s] and 25 to 55 CFM [11.8 and 23.75 L/s], where the typical ou tlet will deliv er 35 CFM [17 L/s] if the plenum static pressure is 1.5 inches [0.37 kPa] and the branch duct length is 10-foot (3 meter) without any balancing orifices. Therefore, the average project will require about 7 2 inch outlets or 5 two and a half inch outlets per nominal ton although more will be needed if the branch ducts are longer, balancing orifices are used, the plenum static pressure is less than 1.5 inches of water [0.37 kPa], or it is desirable to make the system as quiet as possible. For example, two runs with 50% balancing orifices are equal to one branch run without any orifices.

 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 an outlet that is 10 foot [3 m] yielding a



reduction of 40% (30-10=20, 20

 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 m]

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 m] 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 m]; consider the first tee equal to 30 ft [9 m] and elbows equal to 15 ft [4.6 m].

 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.

5=4, 410=40%).

PERIMETER LOOP SYSTEM

DOGLEG SYSTEM

IL00121.CVS

IL00123.CVS

HORSESHOE SYSTEM

'H' SYSTEM

IL00122.CVS

IL00125.CVS

Bulletin 100-135 — Page 2

Plenum (cont.)

 Shotgun Pattern. For the SDAH48 and SDAH60 series units, use 10-inch [254 mm] insulated metal duct for the first 30

percent; then reduce to 9-inch [229 mm] if desired. For the SDAH36 unit, use 9-inch [229 mm] insulated metal duct for the first 40 percent; then reduce to 7-inch [178 mm] if desired. For the SDAH24 unit, 7-inch [178 mm] may be run the entire length.

40 %60 %

9-INCHDIA.

7-INCHDIA.

 24-inch (610 mm) Rule. Use at least 24-inch [610 mm] of straight plenum before any fitting, such as an elbow, tee, or

IL00124.CN

30% MAX.

IL00126.CNV

takeoff. Electric duct heaters require 48 inches [1.2 m]. 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 [1 m] of the Heat Controller supplied sound attenuator supply tubing (SD-

26C or SD-226C) 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 (SD-25 or SD-225) with a 3 foot [1 m] sound attenuator at the end.

 Return Air Duct Attenuation. Use the Heat Controller Return Air Duct (SD-04) sheet metal with acoustical duct liner.

Never use flex duct with a solid plastic liner in place of SD-04.

 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 a dequate number of full

 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

outlets and minimum plenum fittings (full flow).

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 balancing orifices or used or for long branch ducts).

Investigate for blockage or kinks if flow is insu ffi ci ent.

 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 pu mps should be checked in both heating and cooling.

TurboMeter® is a registered trademark of Davis Instruments

INSTALLATION

INSTRUCTIONS

SMALL DUCT HIGH VELOCITY:

SDAH18 Air Handler

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

Bulletin 100-150 / August 2010

INSTALLATION MANUAL

SHAH18 Air Handler

NOTICE TO INSTALLER AND EQUIPMENT OWNER: RETAIN THIS MANUAL AT THE JOB

Il0015 9.CV5

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 Heat Controller SDAH18 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 100-255 System Sizing and Layout bulletin.

SUFFICIENT BUILDING INSULATION IS ESSENTIAL FOR THE MOST ECONOMICAL OPERATION

General Precautions and Safety Tips

Do not attempt to install or startup unit without first reading and understanding the appropriate sections in this manual. Before operating, be sure the unit is properly grounded.

Installation should be in accordance with all local codes and regulations and with the National Fire Protection Association and Underwriters Laboratories applicable standards and regulations. In case of conflict, local codes take precedence.

All electrical wiring should be in accordance with the latest edition of the National Electrical Code and all local codes and regulations.

Condensate piping should be installed in accordance with governing code.

Always install a secondary drain pan when an overflow of condensate could cause damage.

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 .............................................. 7

CHARGING AND STARTUP...................................... 8

Sequence of Operation........................................ 8

Fan Speed ............................................................ 8

Checking Airflow ................................................... 9

Charging a Cooling System .................................. 9

Low Ambient Control Kit ..................................... 11

Charging a Heat Pump System .......................... 11

Mild Weather Kit ................................................. 11

APPENDIX A - Hot Water Coil Capacities ................ 12

APPENDIX B – Chilled Water Coil Capacities .......... 12

APPENDIX C - Specifications ................................... 13

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 revision letter.

INTRODUCTION

The Heat Controller Small Duct High Velocity air handler 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 or 2 ½ 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 throughout the occupied space.

Bulletin 100-150 — Page 2

Heating Only

Blower Cabinet

+ Hot Water Coil)

Cooling Only

Blower Cabinet

+ Cooling Coil

Horiz ontal Flow

Vert ical UpFlow

Figure 1. Unit Arrangement

The Heat Controller SDAH18 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 up-flow 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.

Heating and Cooling

Blower Cabinet + Hot water Coil + Cooling Coil

OUT

IL00148.CV5

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.

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 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 unpacking. Notify carrier of any damage.

CARDBOA RD SUP PORTS

Figure 2. Location of Motor Shipping Supports

Open the blow er access panel to remov e 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 ships installation ready for either horizontal or vertical airflow applications (see Fig. 1) and may be mounted to a structure using the optional mounting rails (SD- 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 100-250, 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.

1 (25) Minimum

Supply plenum

1(25)Minimum

Supply Plenum

Supply plenum

All dimensions in inches (mm).

Side View

Air Flow

18 (457) bottom

clearance for

Top View

24(610) side

clearance for service

Suspended Installation

Side View

service

Return Duct

" 38 "

Return Duct

20 "

38 "

Return Duct

38 "

IL00149.CV5

Figure 3. Minimum Clearances

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. 3.

Bulletin 100-150 — Page 3

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 1 6 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.

SDAH18 SD-01-18

Size of opening

inches (mm)

 20 ½

(365  521)

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.

Figure 4. Typical Horizontal Attic Installation, SDAH18

Bulletin 100-150 — Page 4

Table 2. Secondary Drain Pan

Unit Size Part No.

SDAH18 SD- 94

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

Dimensions

inches (mm)

40 x 22=

(1016 x 559)

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 linear 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 Dist ance of Drain Piping for Different Framing Materials

Frame Lumber:

Max. Horizontal Run, ft. (m)

2 x 4 2 x 6 2 x 8 2 x 10

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

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 or wires. Adjust the straps or wires to pitch the secondary drain pan toward the drain connection.

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 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.

Figure 6. Typical Horizontal Suspension Mounting

Ceiling Mounting

If desired, the unit can be mounted flush to the ceiling (see Fig. 7) using the optional mounting rails (SD–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. Suspend secondary drain pain from the unit with metal straps or wires.

Joist

Ceiling

Mounting Rails

Unit

Metal Straps o r Wires

Figure 7. Typical Ceiling Mounting

IL00164.CV 5

Seconda ry Drain Pa

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 (SD-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.

DUCT CONNECTION

Supply Plenum

The standard supply plenum is a 7-inch (178-mm) diameter duct, although this can be reduced to a 6-inch (152-mm) diameter duct. The SDAH18 plenum adapter (SD-61-18) provides a convenient connection to a 7 in (178-mm) duct.

Bulletin 100-150 — Page 5

on the unit. Mount the adapter with six (6) sheet metal screws. See Figure 10.

Attach the plenum to the adapter by inserting it over the collar. Use three (3) or four (4) equally spaced sheet metal screws to secure the duct to the collar and then tape around the seam with UL 181A aluminum tape. Then wrap the 1-in fiberglass blanket duct insulation around the adapter and seal with UL 181A aluminum tape.

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 ½in (125 x 150, 100 x 190 mm).

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.

Wall

Mounting Rail (SD-95)

Unit

Mounting Board (temporary)

Il00162.Cv5

Figure 9. Typical vertical Rail Mounting

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

Figure 10. Plenum Adapter Installation

Return Duct

The Heat Controller 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 (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 Heat Controller 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 dr op of

0.10 inches of water column at the required airflow. Sound

Bulletin 100-150 — Page 6

attenuation can be accomplished with fabricated duct board, lined sheet metal, or acoustical flex (Part number SD-04-

18). 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.

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 u sing 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.

Switch

Paper Fuse

Leads

Il00156.Cv5

Location of Paper Fuse

Indoor Terminal Block

1234 56 7

Condenser

Switch

Il00157.CNV

Figure 13. Wiring Diagram for Paper Fuse

will dissolve and the switch will open causing th e outside unit to shut down until it is serviced.

Also available is the Heat Controller Condensate U-Trap which features a clear trap that is easy to visually inspect for clogs. The U-Trap is designed for the Heat Controller SDAH18 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 incorporate to tees to accommodate any piping arrangement (Part No. SD-00924).

Do not trap the secondary drain line and do not terminate line into the primary drain line. Run secondary drain line so that any drainage will be immediately known without causing damage to property. A typical location is to terminate the secondary drain line above a windowsill so that the drainage splashes on the window. This will serve as an indicator that there is a problem with the primary drain.

An alternative method of notifying the homeowner about a leakage problem is to use a paper fuse and micro switch. See Fig. 13. Install a micro switch upside down on the side of the secondary drain pan. Making sure that the switch is open. Next, sandwich a paper fuse between the switch and the bottom of the drain pan so that the switch is closed. When water is present in the secondary drain pan, the fuse

Figure 12. Typical Condensate Trap

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 sight glass should also be installed between the filter-drier and expansion valve near the indoor unit.

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. 14. Use the following steps when installing:

1. Remove plastic caps to external equalizer line and distributor inlet.

Bulletin 100-150 — Page 7

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.

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.

Figure 14. Expansion Valve Location

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.

Figure 15. Hot Water Coil Connection

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. Refer to bulletin 100-180 for more information on wiring the System Interface Board (SIB).

Bulletin 100-150 — Page 8

Charging and Startup

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 blo wer 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 Cy cle (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 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 Cy cle (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 Cy cle (Hy dronic 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 SDAH18 comes standard with a 2-speed motor and the Heat Controller SIB (System Interface Board). For more information on this feature refer to Bulletin 100-

180.

Table 4. Motor Amperage versus Airflow

2-Speed

Motor

*Low speed for the optional 2- Speed motor produces half the high speed airflow (1.0 amp @ 230V)

Airflow

CFM (l /s)

200 (94) 1.15 *

300 (142) 1.30 *

400 (189) 1.48 *

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.

Amperage @ 230V

High Speed Low Speed

Checking Airflow.

CAUTION. DO NOT OPERATE BLOWER WITH FREE DISCHARGE OR LOW STATIC PRESSURES (BELOW 1 INCH WC (250 Pa)) TO PREVENT MOTOR FROM OVERLOADING.

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 TurboMeter (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 to tal 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.

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 sy stem pressure drop is

0.25 inches w .c., the total static pressure drop is: 1.6 +

0.25 = 1.85. In this case the static pressure is too high.

Motor Amperage

Bulletin 100-150 — Page 9

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 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.

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.

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 100-160, 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

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. Add balancing orifices to outlets, check for missing

Restrictive duct system. Add outlets, add splitter vane in tee, reduce the

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.

end caps or separated plenum.

number of tees and elbows in plenum, increase plenum size to 9” equivalent.

Bulletin 100-150 — Page 10

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.

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.

In some cases, such as in a hot attic, the liquid line will pick up heat and lose its subcooling. Th is 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 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 appro ximately 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:

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 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:

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!

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 Heat Controller unit 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 Heat Controller

will be about 130 psig (896 kPa) with an 85 to 95°F (29

unit 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 Heat Controller unit 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).

Bulletin 100-150 — Page 11

Charging in Heating Mode.

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 Heat Controller unit 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.

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 Heat Controller System is particularly sensitive to this since it operates at a higher pressure.

To overcome this problem, install a mild weather kit 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.

If the system is started up

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.

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.

Bulletin 100-150 — Page 12

Entering

Water

Temperature

°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)

130 (54.4)

140 (60)

150 (65.5)

160 (71.1)

170 (76.7)

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) 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) 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) 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) 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) 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)

Appendix A – Hot Water Coil Performance

Water

Flowrate

Airflow, SCFM (m

200 (0.09) 300 (0.14) 400 (0.19)

Capacity Capacity Capacity WPD

/s)

Appendix B – Chilled Water Coil Performance

Entering

Water

Temperature

°F °C GPM (L/s) MBH (KW) SHR MBH (K W) SHR MBH (KW) SHR ft. water (KPa)

35 (1.7)

40 (4.4)

45 (7.2)

50 (10.0)

55 (12.8)

Water

Flowrate

3 (0.19) 13.6 (3.98) 0.59 17.2 (5.03) 0.60 19.7 (5.77) 0.62 1.8 (5.37) 4 (0.25) 14.4 (4.23) 0.58 18.9 (5.53) 0.59 22.1 (6.48) 0.60 3.4 (10.15) 5 (0.32) 14.9 (4.37) 0.58 20 (5.86) 0.59 23.8 (6.98) 0.59 5.3 (15.83) 3 (0.19) 11.8 (3.46) 0.60 14.9 (4.38) 0.62 17.2 (5.03) 0.64 1.8 (5.37) 4 (0.25) 12.6 (3.69) 0.59 16.4 (4.81) 0.61 19.2 (5.63) 0.62 3.4 (10.15) 5 (0.32) 13.0 (3.81) 0.59 17.4 (5.10) 0.60 20.7 (6.06) 0.61 5.3 (15.83) 3 (0.19) 10.0 (2.92) 0.62 12.6 (3.69) 0.65 14.6 (4.27) 0.68 1.8 (5.37) 4 (0.25) 10.6 (3.10) 0.61 13.8 (4.05) 0.63 16.2 (4.75) 0.66 3.4 (10.15) 5 (0.32) 11.0 (3.21) 0.61 14.6 (4.28) 0.62 17.4 (5.10) 0.64 5.3 (15.83) 3 (0.19) 8.0 (2.34) 0.67 10.2 (2.99) 0.71 11.9 (3.49) 0.74 1.8 (5.37) 4 (0.25) 8.5 (2.48) 0.66 11.1 (3.25) 0.68 13.1 (3.84) 0.71 3.4 (10.15) 5 (0.32) 8.8 (2.56) 0.65 11.7 (3.42) 0.67 14.0 (4.09) 0.70 5.3 (15.83) 3 (0.19) 6.0 (1.75) 0.76 7.8 (2.30) 0.80 9.3 (2.72) 0.84 1.8 (5.37)

4 (0.25) 6.2 (1.83) 0.74 8.3 (2.44) 0.78 10.0 (2.93) 0.81 3.4 (10.15) 5 (0.32) 6.4 (1.88) 0.73 8.7 (2.53) 0.77 10.5 (3.07) 0.80 5.3 (15.83)

200 (0.09) 300 (0.14) 400 (0.19)

Capacity Capacity Capacity WPD

Airflow, SCFM (m

/s)

Bulletin 100-150 — Page 13

Appendix C – Engineering Specifications

Heat Controller Part No. 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)

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 A00331-001

Size, hp (kW): 1/3 (0.25) Running Speed @ rated airflow: 1650/1350 RPM FLA: 1.5 RLA: Refer to Amperage Chart Bearing Type: Permanently Lubricated Ball

Blower Wheel A00137-003

Airflow, CFM (m 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 (Heat Pump) A00326-001

Nominal Capacity, tons (kW): 1 to 1.5 (3.5 to 5.3) Rated Airflow, CFM (m Min. Airflow, CFM/ton (m Refrigerant Type: R-410A Face Area, ft² (m²): 1.167 (0.108) Number of Rows: 6 Number of Circuits: 3 Fin Density, fins/in. (fins/cm): 15 (6) Fin Type and pattern, in. (cm): Corrugated, 1 x 0.625 (2.540 x 1.588) Tube Diameter, in (cm): 3/8 (0.953) Tube Type: Rifled Expansion Device (AC option) TXV with Bleed Port A00365-001 Expansion Device (HP option) TXV with Bleed Port and Internal Check Valve A00366-001 Liquid Line Connection 3/8 (.953) Suction Connection OD, in. (cm) 5/8 (1.588)

Hot Water Coil (HW option) SDHW-18

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) A00397-G01

Fluid Type Water or Glycol-Water Solution Face Area, ft² (m²) 1.167 (0.108) Number of Rows 6 Number of Circuits 6 Fin Density, fins/in. (fins/cm): 15 (6) Fin Type and pattern, in. (cm): Corrugated, 1 x 0.625 (2.540 x 1.588) Tube Diameter, in (cm): 3/8 (.953) Connection OD SWT, in (cm): 5/8 (1.587)

* The highest speed is not used. ** Static pressure across unit without hot water coil, using 6 inch ID plenum. Motor speed set to high for 2-speed motors.. Static pressure will be greater when using 7 inch ID plenum.

/s): 200 (.094) 300 (.142) 400 (.189) 450 (.212)

/s): 450 (0.212)

/s•kW): 200 (0.027)

INSTALLATION

INSTRUCTIONS

SMALL DUCT HIGH VELOCITY:

SDAH 24, 36, 48 Air Handler

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

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 INSTALL ER AN D 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.

Bulletin 30-20 Installation Manual

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 du ct 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

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.

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 du ct 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-01-2 4

36 SD-01-3 6

48 SD-01-4 8

Return Air Box

Part No.

Size of opening

inches (mm)

 25 ½ (365  648)

 30

(365  775)

(619  775)

UNPACKING

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

Heating or Cooling w/ Heat Pump Coil

Horizontal Flow

Heating or Cooling w/ Chilled Water Coil Only

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

any damage.

Heat Pump Coil w/ Hot Water Coil

IL00010E.cvx

Bulletin 100-155 — Page 3

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 conden ser 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 16-

ches (406-mm) center-to-center or running the wrong

i 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)

(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).

Return AirAdapter (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

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

led unit should be placed over the secondary

assem drain pan supported by rails with rubber pads for isolation to raise the unit above the 1.5-inch (38mm) sides o f the secondary drain pan.

Table 2 shows the secondary drain pans to be used for

zontally mounted modules.

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

Unit

Size

24 SD-94

Part No.

SDAH SDAH + Hot Water Coil

Dimensions

inches (mm)

40 x 22 (1016 x 559)

Part No.

Dimensions

inches (mm)

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

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

rious framing materials and still provide adequate

v drainage.

Table 3. H orizontal Distance of Drai n Pipi ng for Di fferent 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) 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

SD-20B

SD-24B

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

27  29.5†

(686  749)

40  29.5†

(1016  749)

SD-20C

SD-24C

27  41.75†

(686  1060)

40  41.75†

(1016  1060)

Horizontal Suspended Mounting

CAUTION

Do no t h ang unit fr om top of unit c abinet 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

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

IL00038C.CVN

Figure 7. Typical Suspended Mounting

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

Note: Do n ot use restri ctor plate to adj ust 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

Blower Module

Restrictor Plate

Plenum Adapter

Plenum

Insulation Wrap

Figure 9. Supply Plenum Adapter Installation

IL00308.CVX

tape.

Bulletin 100-155 — Page 6

Figure 10. Restrictor Setting

Return Duct

Heat Controller 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 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.

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.

he 24 and 36, if the joists or studs are on 16-inch

For (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.

FRAMING

RETURN AIR BOX

FILTER FRAME

FILTER

FILTER GRILLE

IL00048.CNV

Figure 11. Return Air Box and Filter

Install filter frame into the return air box using four nails or screws. Use the holes furthest from the corners. Insert filter and hold in place by rotating metal clips. Close grille and secure with clips.

Refer to Table 4 for correct Return Duct Adapter selection. Attach the proper return duct adapter to either the Heating or Cooling Module. Then attach the return duct to the adapter and to the return air box using the Q-bands and Q-clips.

The return air adapter ships with an insulation blanket that must be wrapped around the adapter. Tape the seams with UL 181A aluminum tape.

Table 4. Return Duct Adapter

Blower Module +

Unit Size

24 SD-59-2 4 SD-104-24

36 SD-59-3 6 SD-104-36

48 SD-59-4 8 SD-104-48

Cooling Module

Heating Module

+ Cooling Module

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. 11.

Table 5. Approximate Amperages at Given Airflows

Unit Size

*multiply by 1.1 if 208V † for more exact airflow use the chart included with the blower

Airflow,

CFM (L/s)

600 (280)

500 (240) 1.6

400 (190) 1.4

800 (380) 3.2

700 (330) 2.9

600 (280) 2.7

1000 (470) 3.2

900 (425) 2.9

800 (377) 2.8

SDAHxxx-A1

Amps

@230V †*

1.9

Bulletin 100-155 — Page 7

(ship

pedwit

)

Multiple Returns

If more than one return is desired, Heat Controller has a return plenum (HM) module. The HM module is available in three sizes: 24, 36, 48, and it includes a central filter. The HM 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 100-30, Re- turn Plenum Module, for additional information.

PIPING

All piping must be in accordance with all local codes and ordinances.

Condensate Lines

The primary drain pan condensate connection is a ¾inch (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 using Utrap A00924-G03 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 condensation on the outside of the pipe. In some climates or locations it may be necessary to protect trap from freezing in the winter.

Refrigerant Coil Connections

Note

All refrigerant coils are shipped from our fa ctory press urized with nitro gen. They do not contain any refrigerant.

WARNING

To prev ent injury to e yes, fa ce away from the Sc hrader 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 by continuing to press on the depressor. When all the pressure is removed, cut the ends of the connections off.

Pitch ¼ inch per foot (2 cm per m)

53/8

(137 mm)

21/4

(57 mm)

U-TRAP (SD-00924-G03)

SDAH modules

Figure 12. Typical Condensate Trap

IL00046a.cvx

Cut end of connection as shown.

Connection after the end has been cut off.

Bulletin 100-155 — Page 8

WARNING

To prev ent injury, remov e all pressure from coil b efore remov ing conne ction end caps.

CAUTION

When bra zing, purge with nitrog en g as to prevent the formation of oxides.

The refrigerant lines are copper sweat connections. The 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. The valve is shipped loose and should be attached prior to charging. For replacement expansion valves, refer to table 6. Always use new Teflon seals when replacing the TXV.

Remove side panels as shown.

Table 4. Expansion Valve Model numbers

Model

Heat Pump Coils

SDAH24B

SDAH36B

SDAH48B

Nominal

Condenser

2 to 2.5-ton (7 to 9 kW)

3 ton

(10 kW)

3.5 to 4 ton (12 to 13.6

Size

kW)

Valve Part Number

R-410a

A00808-013 2

A00808-014 3

A00808-015 4

Remove nut as shown.

Nom. Valve

Size

Attach and tighten lower connecting nut as shown.

Attach and tighten upper connecting nut as shown.

Bulletin 100-155 — Page 9

Route both the pressure and temperature tubes as shown.

Tighten the pressure tube nut as shown.

Secure bulb with cork tape as shown.

Water Connections

If you are installing the hot water coil, remove the side coil access panel and cut away the insulation. Slide the coil into the cabinet and secure with brackets supplied with the hot water coil. Install the access panel after the coil is in place.

The thermal measuring bulb is placed as shown. It

needs to be in contact with copper tube.

(a) Hot Water Coil

BLEED VALVE (VENT)

OUT

BLEED VALVE (DRAIN)

(b) Chilled Water Coil

Figure 13. Water Coil Connections

AIRFLOW

IL00054b.CVN

Bulletin 100-155 — Page 10

All water connections are 7/8-inch (22mm) sweat connections. Sweat the water connections, than fill the system. Bleed the air from the coil by backing off the screw inside the bleed valve for venting (Fig. 13).

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 blow-off 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 s upply before wiring unit to prev ent 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.

Use a separate 1 ph - 230/208V – 60/50 Hz power supply with a 15 amp breaker and appropriate wire gauge per code.

The System Control Box comes standard with all SDAH series blower/coil module. The control box is designed to operate with a two speed motor with full speed being used for heating and cooling. The second speed operates at 50% of full speed and is used for ventilation mode only. The SIB includes a 24-volt transformer, a capacitor, and the controlling circuit board. Refer to bulletin 100-180 for installation instructions for the SIB.

STARTUP

! IMPORTANT !

The most important step when installing the small d uct high v elocity s ystem is making sur e it ha s the correct airflow. Be sure to reco rd the amperage and voltage of ev ery system in order to v erify the airflow throug h the unit. Also, measure the airflow a t ea ch outlet to v erify the airflow in each ro om. Both methods ar e 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 (H eat Pu mp). 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 energ ize the rev ersing 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 (Hea t Pu mp). 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 heat i ng .

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.

Bulletin 100-155 — Page 11

Heating Cy cle (Electric Heat-O nly). 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 C ycle. When the thermostat is satisfied and the fan switch is set to “AUTO”, the “G” circuit is open and the motor will slowly come to a stop.

Checking Air Flow

CAUTION

Do no t ope rate blo wer with fr ee discharge or lo w static pr essures (b elow .5-inch w.c. to prevent motor from overloading.

After the system is installed and before charging the 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.

As a recommended further check on airflow, use a veloci-meter 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. For a 2-inch outlet, multiply the knots by 2 to get the CFM of the outlet. For a 2 ½ inch outlet, multiply the knots by 2.37 to get the CFM of the outlet. The CFM will have an accuracy of within 10%. (Multiply ‘knots’ by 0.94 to obtain L/s.)

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 all SDAH blower/coil modules.

Note: These tables are for th e specific motor in stalled in ea ch blower mo dule. Be sure the tab le used appl ies to th e c orrect model number that is shown on the table.

Use Table 5 to correct the airflow.

Chec

k Stati

c Pres sure Measure the external static

pressure in the supply plenum at least two feet (610 mm) from the unit and verify that it is within the allowable range.

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 syste m pressure drop is 0.25 inches w.c, the total static pressure drop is: 1.6 +

0.25 = 1.85. In this case the static pressure is too high. Check Moto r Amperag e. Remove the control box

cover and measure the current with an amp meter. This should be measured on the purple wire between the control box and the motor with the letters “clmpmter” printed on the wire. Compare this reading to the Motor Amperage-Airflow table enclosed as a separate sheet in the Blower Module carton.

Table 5. 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.

Low static, high amperage Large number of outlets.

High Static, Low Amperage

Restrictor setting to high.

Restrictive duct system. Add outlets, add splitter vane in tee, reduce the number of

Open restrictor to table 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.

Close restrictor to proper amperage, or Add balancing orifices to outlets.

Close restrictor to obtain proper amperage.

tees and elbows in plenum, increase plenum size to 9” equivalent, or Open restrictor to proper amperage.

Bulletin 100-155 — Page 12

How to Measure Outlet Airflow

The Davis TurboMeter is the ideal instrument for measuring airflow for both the 2 and 2 ½ inch round outlets. This instrument can be used to determine how much air duct leakage is in the system by comparing the total airflow using the turbo meter to the motor amperage chart that comes with the SDAH.

How to Measure Static Pressure

Measure the supply plenum static pressure at least 18inches (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. 14.

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.

To assure an accurate measurement, follow the procedure listed below.

1. Slide the ON switch to the Knots position. This is roughly equal to 100 ft-per-min.

2. Place the meter against the outlet with the fan centered over the outlet.

3. Record th e KNOTS reading.

4. For a 2 inch outlet, multiply the KNOTS by 2.0 to obtain CFM. For a 2 ½ inch outlet, multiply the KNOTS by 2.37 to obtain CFM.

5. Use the Heat Controller Service Report Form to record your system readings and to determine the system total airflow.

Example: A 2-inch round outlet reads 16.3 knots. Multiply 16.3 by

2 to obtain 32.6 CFM. Repeat this for each outlet in the system and add them

together to determine the total CFM. This value can then be compared to the blower amperage charts to insure minimal air leakage.

Figure 14. 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. 15.

Figure15. U-Tube Manometer

Bulletin 100-155 — Page 13

Charging the System

Charging – Cooling M ode. 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.

The following procedure is only valid for charging the system during the cooling mode.

After the refrigerant lines and evaporator have been carefully leak tested and evacuated, release the R-410a 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 75°F (23.9°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.

Charge and operate the heat pump in accordance with these instructions and the instructions provided by the manufacturer of the outdoor unit.

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. Then recheck the charge during the heating season to be sure the system is not over charged.

Charging – Heat 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.

Typically, in the heating mode, a High Velocity System will have a slightly higher discharge (LIQ.) pressure, and in cooling mode a High Velocity System will have a slightly lower suction (SUC.) pressure.

Some outdoor heat pump units include a manual highpressure switch. With the lower airflow and higher temperatures, the discharge pressure will typically run higher than a conventional system. 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.

High Head Heat (Mild Weather Kit). When any heat pump is operated during mild weather (temperatures above 50°F [10°C]), the compre ssor may trip out on the high-pressure limit. High Velocity systems are particularly sensitive to this since it operates with a lower air-

r more information.

flow. Contact the manufacturer f

To overcome this problem, install a control to cycle or modulate the outdoor fan based on the compressor discharge pressure.

Sub-cooling Meth od. 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 and 8°F (2 to 5°C). The unit should ALWAYS have some amount of sub-cooling. To be sure there is enough sub-cooling, especially if the unit is in a hot attic, check the liquid line sight glass near the evaporator for bubbles or 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.

2. Measure and record the liquid line temperature using an accurate metal or glass thermometer, or thermo-

Bulletin 100-155 — Page 14

couple. Tape or strap the sensor firmly against the surface of the liquid line and cover with insulation.

3. Determine the sub-cooling with the following 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 LIQUI D CHARGE INTO SUCTION PORT.

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 MAI NTAIN PROPE R HEAT P UMP OPERATION, DO NO T STRAP T HE LIQUID A ND SU CTION LI NES TOGETHER FOR H EAT PUM P SYSTEMS.

Superheat M ethod. Do not charge the system based

on superheat. Superheat measurements should only be used to verify that the expansion valve is working properly.

To measure the superheat, use the following:

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 Heat Controller

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 Heat

Controller System will be about 130 psig (898 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 a small duct high velocity 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 5ton 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 outdoor unit manufacturer to determine what controls are compatible with the outdoor unit.

Maintenance

When service is required to the motor or the wheel, the entire assembly may be removed as a unit (see figure

16). The SDAH series units are 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 B ALANCE, DO NO T G RAB 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.

Bulletin 100-155 — Page 15

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.

Figure 16. Removal of the Motorized Blower Assembly

Bulletin 100-155 — Page 16

Figure 17. Horizontal Configuration Chart

Blower Performance

External Static Pressure, in. water (Pa)

Model CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps CFM (L/s) Amps

SDAH24x-A1 760 (360) 2.3 700 (330) 2.1 640 (302) 2.0 550 (260) 1.7 450 (212) 1.5

SDAH36x-A1 1380 (617) 5.2 1300 (613) 4.9 1200 (566) 4.5 1090 (514) 4.0 950 (448) 3.6

SDAH48x-A1 1480 (698) 5.0 1430 (674) 4.4 1360 (642) 4.5 1220 (575) 4.0 930 (439) 3.1

1.0 (250) 1.25 (310) 1.5 (370) 1.75 (435) 2.0 (500)

60 Hz – 230V

Bulletin 100-155 — Page 17

SDAH Specifications

Model No. SDAH24 SDAH36 SDAH48

Electrical Characteristics 208 – 230 Volts / 60 / 1 phase

Size, HP (kW) 1/2 (0.37) 1 (0.75) 1 (0.75)

Motor

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)

Nominal* Air Flow Rate, cfm (L/s) 600 (283) 800 (377) 1100 (519)

Plenum Static Pressure, iwc, (Pa) 1.5 (373) 1.5 (373) 1.5 (373)

Sound Pressure Level

Minimum Plenum Size, ID, inch (mm) 7 (178) 9 (229)

Shipping Weight, lb (kg) 82 (37) 94 (43) 111 (50)

Overall Dimensions, in. (mm) H x W x D

Full Load Amps 3.3 4.8 4.8

Capacitor, mfd. 10 10 10

Speed, RPM 1625/800 1625/800 1625/800

dB(A) 56 56 58

NC 50 47 50

17.5 x 25 x 26

(445 x 635 660)

17.5 x 30 x 26

(445 x 762 x 660)

17.5 x 38 x 26

(445 x 965 x 660)

A/C or Heat Pump Coil Option

Model No. 24 36 48

Compatible Condenser Size, Ton (kW) 1.5-2.0 (5.3-7.0) 2.5-3 (8.8-10) 3.5-4 (12.3-14)

Net Face Area, ft2 (m2) 1.92 (0.178) 2.34 (0.217) 3.48 (0.32)

Tube diameter, in. (mm) 3/8 (9.5)

Number of rows 4

Fins per inch (cm) 14 (355)

Heat Pump

Condensate Connection, in. (mm) FPT 3/4 (19)

Refrigerant R-410A*

Suction line O.D., in. (mm) 7/8 (22.2)

Fin Type corrugated

Number of Circuits 6 6 6

Valve, R-410A, Part No. A00808-013 A00808-014 A00808-015

Liquid line, in. (mm) OD 3/8 (9.5)

Chilled Water Coil Option

Model No. 24 36 48

Net Face Area – sq. ft. (m2) 1.921 (0.178) 2.338 (0.217) 3.483 (0.324)

Water Coil

Water Connection Size, ODF Sweat – in. (mm) 7/8 (22.2)

Condensate drain connection size, FPT – in. (mm) 3/4 (19)

Tube Diameter – in. (mm) 3/8 (9.5)

No. of Rows 6

Fin Density – fins/in. (fins/m) 15.5 (610)

10/2010

Heat Controller Small Duct, High Velocity Quick Start Manual

Specifications and Main Features

Frequently Asked Questions

User Manual