Modine Manufacturing SSD, SSH, SCW Service Manual
8-504.6
5H101548A2
February, 2014
INSTALLATION AND SERVICE MANUAL
The SLIMLINE PERFORMER Ceiling Cassette
Models SSD, SSH and SCW
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, injury or
death, and could cause exposure to substances
which have been determined by various state
agencies to cause cancer, birth defects or other
reproductive harm. Read the installation, operating
and maintenance instructions thoroughly before
installing or servicing this equipment.
IMPORTANT
1. The use of this manual is specifically
intended for a qualified installation and
service agency. A qualified installation and
service agency must perform all installation
and service of these appliances.
2. SSD and SSH units contain the refrigerant
R-410A. Review the R-410A Material Safety
Data Sheet (MSDS) for hazards and first aid
measures.
3. Refrigerant charging should only be carried
out by an EPA-certified air conditioning
contractor.
This unit contains R-410A high pressure refrigerant.
Hazards exist that could result in personal injury or
death. Installation, maintenance, and service must only
be performed by an HVAC technician qualified in R410A refrigerant and using proper tools and equipment.
Due to much higher pressure of R-410A refrigerant, DO
NOT USE service equipment or tools designed for
refrigerants other than R410A.
WARNING
Inspection upon Arrival
1. Inspect unit upon arrival. In case of damage, report
immediately to transportation company and your local
factory sales representative.
2. Check serial plate on unit to verify that the power supply
meets available electric power at the point of installation.
3. Inspect unit received for conformance with description of
product ordered (including specifications where
applicable).
Please be sure to leave it with the owner when you leave the job.
This manual is the property of the owner.
SPECIAL PRECAUTIONS
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN
THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE,
EFFICIENT, AND TROUBLE-FREE OPERATION. IN ADDITION,
PARTICULAR CARE MUST BE EXERCISED REGARDING THE
SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO
PROPERLY ADDRESS THESE CRITICAL AREAS COULD
RESULT IN PROPERY DAMAGE OR LOSS, PERSONAL INJURY,
OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY
MORE RESTRICTIVE LOCAL OR NATIONAL CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation which,
if not avoided, WILL result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which,
2.
if not avoided, COULD result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if
3.
not avoided, MAY result in minor or moderate injury.
IMPORTANT: Indicates a situation which, if not avoided, MAY
4.
result in a potential safety concern.
DANGER
Appliances must not be installed where they may be
exposed to potentially explosive or flammable atmosphere.
WARNING
1. Disconnect power supply before making wiring
connections to prevent electrical shock and equipment
damage.
2. All appliances must be wired strictly in accordance with
the wiring diagram furnished with the appliance. Any
wiring different from the wiring diagram could result in a
hazard to persons and property.
3. Any original factory wiring that requires replacement
must be replaced with wiring material having a
temperature rating of at least 105°C.
4. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than
rated voltage.
5. When servicing or repairing of this equipment, use only
factory-approved service replacement parts. A
complete replacement parts list may be obtained by
contacting Modine Manufacturing Company. Refer to
the rating plate on the appliance for complete appliance
model number, serial number and company address.
Any substitution of parts or controls not approved by the
factory will be at the owner’s risk.
CAUTION
1. SSD and SSH units contain the refrigerant R-410A.
Review the R-410A Material Safety Data Sheet
(MSDS) for hazards and first aid measures.
2. Refrigerant charging should only be carried out by an
EPA-certified air conditioning contractor.
2
8-504.6
CAUTION
1. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the
rated voltage.
2. Units not approved for use in potable water systems.
3. Hot water supplied to the hot water heating option
must not exceed 200ºF temperature or 125 PSIG
pressure.
4. Do not overcharge the refrigeration system. This can
lead to elevated compressor discharge pressure and
possibly flooding to the compressor with liquid.
5. Do not attempt to reuse any mechanical or electrical
component which has been wet. Such component
must be replaced.
IMPORTANT
1. Make sure the ceiling grid is supported separately
from the appliance. The ceiling must not be
supported by any part of the appliance, fascia or
any associated wiring or pipe work.
2. Start-up and adjustment procedures should be
performed by a qualified service agency.
3. All refrigeration checks must be made by a qualified
R-410A refrigeration technician.
4. Do not release refrigerant to the atmosphere. When
adding or removing refrigerant, all national,
state/province and local laws must be followed
5. To check most of the Possible Remedies in the
troubleshooting guide listed in Tables 23.1 through
26.1, refer to the applicable sections of the manual.
Table of Contents
Inspection on Arrival
Special Precautions
Hazard Intensity Levels
SI (Metric) Conversion Factors
Unit Location
Installation
Start-Up Procedure
Start-Up Sheet - Example
Dimensions
Technical Data: SSD and SSH
Technical Data: Condensers for SSD Units
Technical Data: Condensers for SSH Units
Technical Data: SCW Units
Electrical Data – Ceiling Cassettes
Exploded Unit Drawing & Parts List: SCW 08 & 12
Exploded Unit Drawing & Parts List:
SSD/SSH/SCW 18 - 42
Maintenance – Indoor Unit
Troubleshooting – Indoor Unit
Replacement Parts
Model Nomenclature
Serial Plate Example
10-14
23-26
1
2
2
3
3-4
4-7
7-8
9
15
16
17
18
19
20
21
22
26
26
26
UNIT LOCATION
x
Table 3.1
SI (Metric) Conversion Factors
To Convert Multiply By To Obtain To Convert Multiply
“W.C. 0.249 kPa feet 0.305 m
ºF (ºF-32) x 5/9 ºC Gal/hr 0.00379 m³/hr
BTU 1.06 kJ Gal/hr 3.79 l/hr
BTU/ft3 37.3 kJ/m³ gallons 3.79 l
BTU/hr 0.000293 kW Horsepower 746 W
CFH (ft3/hr) 0.000472 m³/min inches 25.4 mm
CFH (ft3/hr) 0.00000787 m³/s pound 0.454 kg
CFM (ft3/min) 0.0283 m³/min psig 6.89 kPa
CFM (ft3/min) 0.000472 m³/s psig 27.7 “W.C.
By
To Obtain
UNIT LOCATION
DANGER
Appliances must not be installed where they may be
exposed to potentially explosive or flammable
atmosphere.
Unpacking
Remove the banding straps and lift the cardboard lid.
Remove the fascia, packed in bubble wrap, and polystyrene
packing pieces to expose the unit.
When removing the unit chassis from the box, the four
corner brackets should be utilized for lifting. In order to
protect the fascia from dirt and damage, it should be
returned to the box until it is ready to be installed.
Blank Off Pieces
When branch ducting is to be used, polystyrene pieces for
blanking off fascia openings are included with the fascia
packing. Up to two opposing sides may be blanked off. See
Installation – Duct Collars.
Positioning
Before any installation work commences, the condensing
unit location (where applicable), pipe work sizes and routes
should be designed in accordance with good refrigeration
practice.
The unit installation position should be selected with the
following points in mind:
1. The appliance must be installed on a structure that is
suitable to support the total weight of the appliance,
piping, refrigerant and condensate.
2. Piping, electrical panel and condensate pump access
panel should be readily accessible for maintenance
purposes. A clearance of 2 feet is recommended
around the electrical panel and condensate pump
access panel.
3. The unit should not be positioned less than 5 ft. from a
wall or similar obstruction, or in a position where the
discharge air could blow directly on to the thermostat.
4. The unit should not be positioned directly above any
obstructions.
5. The unit must be installed square and level.
6. The condensate drain should have sufficient downward
slope (1” in 100”) in any horizontal run between unit and
drain. Maximum condensate pump lift is 30”.
7. There should be sufficient room above the false ceiling
for installing the unit. Minimum distance as shown in
Figure 3.1 and Table 3.2.
8. In case of high humidity, clogged or damaged
condensate piping, incorrect installation or faulty
condensate pump, water may drip from the unit. Do not
install the appliance where dripping water can cause
damage.
Figure 3.1
Minimum Distance to Ceiling
30”
ma
A
Table 3.2
Minimum Distance to Ceiling
Models A
SCW 08 & 12 12¾”
SCW 18 & 20 11½”
SCW 33, 36 & SSD/SSH 18 - 42 13½”
Ceiling Opening Sizes
An opening in the false ceiling will then have to be cut to the
size shown in Table 3.3.
Table 3.3
Ceiling Opening Sizes
Models L x W
SCW 0/8 & 12 23” x 23”
SSD/SSH/SCW 18, 20 & 24 34” x 34”
SSD/SSH/SCW 30, 33, 36 & 42 46” x 34”
3
8-504.6
UNIT LOCATION/INSTALLATION
A
A cardboard template for ceiling cut-out and rod positions is
included with the unit.
Positioning Electro-Mechanical Thermostat
In addition to positioning the unit correctly, it is very
important to locate the wall mounted thermostat in the
optimum position to ensure good temperature control.
Therefore the installation should be selected with the
following points in mind:
1. Position the thermostat approximately 48 inches above
floor level.
2. Do not position thermostat where it can be di rectly
affected by the unit’s discharge air stream.
3. Avoid external walls and drafts from windows and doors.
4. Avoid positioning near shelves and curtains as these
restrict air movement.
5. Avoid heat sources e.g. direct sunlight, heaters, dimmer
switches and other electrical devices.
INSTALLATION
IMPORTANT
Make sure the ceiling grid is supported separately from
the appliance. The ceiling must not be supported by any
part of the appliance, fascia or any associated wiring or
pipe work.
Hanger Bolts
The hanger bolts can now be installed (use 3/8” all thread
rod) at the centers shown in Figure 4.1 and Table 4.1.
Figure 4.1
Hanger Bolt Mounting Dimensions
B
Installation Guide
An installation guide is included in the Airedale Owner
Information packet provided with the unit. Prepare the
installation guide by folding the flat metal piece, by hand,
along the perforations as shown in Figure 4.2.
Figure 4.2
Installation Guide Setup
FOLD SIDE BACK
FOLD TAB UP
The unit can now be lifted onto the hanging rods and levele d
at the correct distance from the ceiling with the aid of the
installation guide.
1. Hold the tab on the installation guide against the bottom
of the cassette case with the guide pointing away from
the cassette. See Figure 4.3.
2. Adjust the height of the cassette until the guide is level
with the bottom of the false ceiling.
Figure 4.3
Installation Guide Position
Table 4.1
Hanger Bolt Mounting Dimensions
Models A B
SCW 08 & 12 19½” 23”
SSD/SSH/SCW 18, 20 & 24 28½” 31½”
SSD/SSH/SCW 30, 33, 36 & 42 28½” 43½””
Check the strength of the unit mounting hanger bolts. Refer
to Tables 15.1 and 18.1 for unit weights.
4
OUTER CASE
INSULATION
A
CASSETTE CASE
TAB
FALSE CEILING
GUIDE IN POSITION
INNER CASE
INS U L A T IO N
3. Secure the unit in position with locknuts and washers on
both sides of the unit bracket. Ensure the threaded rod
does not protrude more than 2” below the mounting
bracket as shown in Figure 5.1.
8-504.6
INSTALLATION
Figure 5.1
Threaded Rod Dimension
3/8”
Threaded Rod < 2”
Condensate Piping
The unit is supplied with a 3/8" ID flexible hose for
connection to copper or plastic drain piping.
When installing the unit the following points should be
remembered:
1. Maximum pump lift is 30”.
2. The highest point in the condensate piping should be as
close to the unit as possible. See Figure 5.2.
Figure 5.2
Condensate Piping
INCORRECT CORRECT
3. Condensate piping should sl ope downwards in the
direction of water flow with a minimum gradient of 1” in
100”. There must not be any uphill gradients other than
in the first 30” of piping from the unit.
4. When multiple units are connected to a comm on
condensate drain, ensure the drain is large enough to
cope with the volume of condensate from all units. It is
also recommended to have an air vent in the condensate
piping to prevent any air locks.
5. Condensate piping must not be installe d where it may be
exposed to freezing temperatures.
Duct Collars
Branch duct and fresh air duct collars can be attached to the
unit chassis by following the steps below:
1. Up to 2 branch ducts can be attached per unit.
2. Refer to the relevant dimensional drawing on pages 10 to
14 to become familiarized with knock-out hole locations.
3. The insulation is pre-cut to aid location and removal of
the relevant section. Rub hand across surface of
insulation to reveal exact location of knock-out.
4. Remove the metal knockout from the chassis.
5. Attach the duct collar to the chassis using self tappin g
screws.
6. Replace washable filter with the pleated filter provided
with fresh air duct collar kit.
Note: See Figures 10.1, 11.1, 12.1, 13.1 and 14.1 for
Branch Duct and Fresh Air Duct locations and dimensions.
Piping Installation – SSD and SSH Units
CAUTION
1. SSD and SSH units contain the refrigerant R-410A.
Review the R-410A Material Safety Data Sheet
(MSDS) for hazards and first aid measures.
2. Refrigerant charging should only be carried out by an
EPA-certified air conditioning contractor.
Note: R-410A refrigerant is the only approved refrigerant for
this system.
The unit should be piped up in accordance with good
refrigeration and/or plumbing practices.
The outdoor condensing unit must be connected to the
indoor unit coil using field supplied refrigerant grade (AC R)
copper tubing that is internally clean and dry. Units should
be installed only with the tubing sizes for the approved
system combination as specified in Tables 16.1 and 17.1.
Condensing units are factory charged with refrigerant for a
matching indoor coil plus 15 feet of field supplied lines.
See the installation and maintenance manual provided with
the condensing unit for installation, evacuation and system
charge information.
Piping Installation – Hot/Chilled Water Coils
1. Branch p iping to and from the unit should include s wing
joints to allow for expansion and contraction of the
piping without placing a strain on the unit coil.
2. Install pipe unions and shut-off valves in lines to and
from each coil to allow maintenance or replacement of
unit without shutting down and draining entire system.
See Figure 6.1.
3. Include a circuit setter in return line for water flow
regulation.
4. A drain valve (hose bib) should also be provided for
each coil line to allow removal of water from the coil if
located in an area subject to freezing.
5. It is advisable to use a pipe line strainer before each
coil.
6. Provide adequate pipe hangers, supports, or anchors to
secure the piping system independently of the unit.
5
8-504.6
INSTALLATION
Figure 6.1
Hot/Chilled Water Coil Piping Installation
Piping Insulation
Refrigerant, chilled water and condensate pipes should be
insulated right up to the unit chassis to prevent condensation
which can damage the ceiling and objects located below the
piping. Chilled water valves must also be insulated to
prevent sweating.
Wiring
WARNING
1. Disconnect power supply before making wiring
connections to prevent electrical shock and
equipment damage.
2. All appliances must be wired strictly in accordance
with the wiring diagram furnished with the appliance.
Any wiring different from the wiring diagram could
result in a hazard to persons and property.
3. Any original factory wiring that requires replacement
must be replaced with wiring material having a
temperature rating of at least 105°C.
4. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than
rated voltage.
This equipment in its standard form is designed for an
electrical supply of 208-230V, 1Ph, 60Hz. When connection
to a 115V, 1Ph, 60Hz supply is necessary, a factory
mounted step up transformer must be fitted to the unit.
Any damage to or failure of units caused by incorrect wiring
of the units is not covered by warranty.
Once the refrigeration pipe work is complete, the electrical
supply can be connected by routing the cable through the
appropriate casing hole and connecting the supply and
ground cables to the unit’s power terminals. A plastic sleeve
is provided inside the control panel. Low voltage control
wiring must run through the plastic sleeve on the inside of
the control panel.
Terminal Strip Connections
The terminal strip connections are designed to clamp down
on the wires. To properly connect the wires to the terminal
strip:
1. Push a small flat head screwdriver into the square hole
on the terminal. Press firmly until the screwdriver hits
the back stop and opens the terminal. See Figure 6.2.
2. Remove approximately 3/8” of insulation from the end of
the wire and push the stripped wire into the oval hole in
the terminal.
3. Remove the screwdriver. Pull on the wire to make sure
that it is securely clamped in the terminal.
4. Make sure that the terminal clamp is in contact with bare
wire (insulation removed).
Figure 6.2
Terminal Strip
CAUTION
Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
Installation of wiring must conform with local building codes,
or in the absence of local codes, with the National Electric
Code ANSI/NFPA 70 – Latest Edition. Unit must be
electrically grounded in conformance to this code. In
Canada, wiring must comply with CSA C22.1, Electrical
Code.
Electric wiring must be sized to carry the full load amp draw
of the motor, starter and any controls that are used with the
unit. See Table 19.1 for Electrical Data.
6
Fascia Assembly
Once the services have been connected, the four (4) fascia
mounting bolts can be unscrewed approximately 1” from the
condensate tray support channels.
8-504.6
INSTALLATION/START-UP PROCEDURE
F
The fascia can now be unpacked for fitting to the unit
chassis. Ensure the black fir tree fasteners holding the
fascia polystyrene are pushed in firmly in case of transit
vibration. If a fascia aperture needs blanking off, then take
one of the polystyrene blanking pieces and push it into the
recess in the polystyrene fascia insulation. See Figure 7.1.
Install the fascia by removing the inlet grilles and filters,
locating the four fascia mounting bolts on the chassis
through the four keyhole brackets on the fascia and then
sliding the fascia sideways until it locks into position.
Note: Up to two non-adjacent sides can be blanked off.
Figure 7.1
Fascia Blanking Piece
ascia Blanking Piece
Side view of fascia
Note: Make sure the foam insulating strip profile on the
fascia matches the square and angled corners of the
unit housing.
Before tightening the fascia to the unit, connect the two
halves of the vane motor’s plug and socket connection
(medium and large size units).
On microprocessor controlled units, ensure that the display
panel cable is routed to the electrical panel and securely
fastened to its connector on the microprocessor circuit
board. (Refer to the unit’s electrical wiring schematic). Take
care to ensure that the connector is connected in the proper
orientation and that the wires are not routed such that they
may become trapped, cut, broken or chafed.
The fascia can now be tightened up to the unit chassis until
a good seal is obtained between fascia and chassis.
Note: Do not over tighten the bolts. To do so may cause
damage to the fascia.
With filters in place, the inlet grilles can now be fitted to the
fascia to complete the installation.
START-UP PROCEDURE
IMPORTANT
Start-up and adjustment procedures should be
performed by a qualified service agency.
See start-up sheet example - Figure 9.1
8-504.6
Pre-Start Checks
Once installation is complete it is important that the following
pre-start checks are made:
1. All piping is complete and insulate d where necessary.
2. All fans are able to rotate freely.
3. The unit and interconnecting piping have been
evacuated correctly and the condensing unit service
valves are open (SSD and SSH units only).
4. All electrical connections (both power and control) are
properly terminated.
5. All condensate drains are installed correctly.
6. The power supply is of the correct voltage and
frequency.
7. The units are properly grounded in accordance with
current electrical codes.
8. For microprocessor controlled units, check that the
display panel cable is properly connected to the
microprocessor main circuit board and that the jumper
links are correctly set (refer to unit wiring schematic). If
the links are set incorrectly, remove main power supply
before making any changes.
9. For microprocessor controlled units, check that the
battery on the main circuit board is in place and properly
connected. Check also that the batteries are installed in
infrared/pendant transmitter. When a pendant
transmitter is used, ensure it is properly located on to the
wall mounting bracket.
SSD and SSH Units – Control Circuit Checks
Note: See the installation and maintenance manual
provided with the condensing unit for start-up information.
1. Ensure that the condensing unit start-up procedure has
been carried out, as detailed in the condensing unit
installation and maintenance manual.
2. The compressor should be isolated b y removing the
connection at the Y1 terminal on the indoor unit. Main
power can now be applied to the indoor and outdoor
units. A system electrical check can now be carried out.
3. Switch on the indoor unit via the infrared/pendant
transmitter or wall mounted thermostat and check that
the fan cycles correctly. - Note, in some models there is a
2 minute fan run on time to remove residual heat from
the unit, if the unit is switched off during the heating
mode.
4. On models with microprocessor controls, check that the
High, Medium and Low fan speeds are operating
correctly by changing the fan speed via the transmitter.
5. On medium and large size units, check that the motorized
vane sweep functions correctly by toggling the function on
or off, either via the transmitter (micro units) or via the toggle
switch on the side of the electrical panel (electro-mechanical
units).
6. On micro controlled units, should it be required, check
that the built-in timer function is programmed and
operating correctly. When the timer is activated, the red
LED on the fascia display panel should be lit.
7
START-UP PROCEDURE
7. Check the operation of the condensate pump by pouring
7-8 ounces of water down the pump outlet, switch the
unit on, select cooling mode and the lowest possible
temperature set point then observe the water being
pumped from the unit.
8. Where fitted, check the operation of the hot water valv e
or the electrical heat elements by switching the system to
the heating mode and selecting the highest possible
temperature set point.
9. The compressor signal Y1 (disconnected from the indoor
unit in step 1) can now be re-connected and main power
applied to the system.
Note: The 24V power for the indoor unit control circuit is
supplied from a unit factory-installed transformer. When the
indoor and outdoor units are supplied from separate main
supplies, care must be taken to ensure that the outdoor unit
is isolated whenever the indoor unit power is removed.
Failure to do so may result in freeze ups and other damage
to the unit.
Chilled Water Unit – Control Circuit Checks
A thorough pipe work check and pressure test should be
performed before the unit controls are set up
1. Isolate the unit from the chilled water supply. A system
electrical check can now be carried out.
2. Switch on the indoor unit via the infrared/pendant
transmitter or wall mounted thermostat and check that
the fan cycles correctly. - Note, in some models there is a
2 minute fan run on time to remove residual heat from
the unit, if the unit is switched off during the heating
mode.
3. On models with microprocessor controls, check that the
High, Medium and Low fan speeds are operating
correctly by changing the fan speed via the transmitter.
4. On medium and large size units, check that the motorized
vane sweep functions correctly by toggling the function on
or off, either via the transmitter (micro units) or via the toggle
switch on the side of the electrical panel lid (electromechanical units).
5. On micro controlled units, should it be required, check
that the built-in timer function is programmed and
operating correctly. When the timer is activated, the red
LED on the fascia display panel should be lit.
6. Check the operation of the condensate pump by pouring
7-8 ounces of water down the pump outlet, switch the
unit on, select cooling mode and the lowest possible
temperature set point then observe the water being
pumped from the unit.
7. Check the operation of the chilled water valve by
switching the system to the cooling mode and forcing a
call for cooling.
8. Where fitted, check the operation of the hot water valve
or the electrical heat elements by switching the system to
the heating mode and forcing a call for heat.
9. Allow chilled water to enter the unit and vent air from the
unit by opening the 1/4" air bleed. Re-tighten the bleed
screw once all air has been removed.
10. Repeat steps 1-4 above for all units in the same system.
The units are now ready for the system balance to be
performed.
8
Sequence of Operation
Electro-Mechanical Controls: A 24V signal from the
thermostat to terminal G supplies power the blower motor(s),
condensate pump and vane motor (if equipped). A toggle
switch on the control box can be used to switch the
oscillating vanes on or off. The condensate pump will run
continuously, as long as the blower is energized. A call for
heating, at terminal W, or cooling, at terminal Y, will energize
the water valve actuator and allow water to flow through the
cassette coil. When the call for heating or cooling is satisfied
the valve will close.
If the temperature drops below the set-point of the coil freeze
stat, the water valve with automatically open to circulate
water through the coil.
If the condensate float switch detects a high level of water in
the condensate tray, the switch will open, activate the
condensate pump and disable the heating/cooling signal
until the water level drops down to normal.
Micro-Processor Controls: See the Infra-Red Remote
Controller Installation and Service Manual, 8-507.
8-504.6
START UP SHEET – EXAMPLE
Figure 9.1
Start Up Sheet – EXAMPLE
9
8-504.6
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