Unico 4860 User Manual

Bulletin 30-20 / Dec. 2010
© Copyright 2010 Unico, Inc.
INSTALLATION MANUAL
FOR
‘M’ SERIES MODULAR
AIR HANDLER UNITS
IL00004a.CVN
GENERAL
The information on the following pages is to help the
installer save time, provide the best possible installation
and ensure continuous trouble-free operation.
SCOPE
These instructions apply to the Unico “M” Series mod-
ular air handler units. For heat pumps, refer to Bulletin
30-24 for additional instructions. Installation instructions
for the air distribution system are covered in Bulletin 30-
05. Before beginning any installation a detailed system
layout must be done in accordance with the System Siz-
ing and Layout Procedure, Bulletin 40-40 and the Com-
ponent Layout Instructions, Bulletin 40-30.
NOTICE TO INSTALLER AND EQUIPMENT
OWNER: RETAIN THIS MANUAL AT THE JOB.
FULL BUILDING INSULATION IS ESSENTIAL
FOR THE MOST ECONOMICAL OPERATION
GENERAL PRECAUTIONS AND SAFETY TIPS
Do not attempt to install or startup unit without first
reading and understanding the appropriate sections in
this manual.
Before operating, be sure the unit is properly grounded.
Installation should be in accordance with all local codes
and regulations and with the National Board of Fire Un-
derwriters 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 lo-
cal codes and regulations. The unit is safety certified to
UL 1995 and listed with ETL.
Always install a secondary drain pan when an overflow
of condensate could cause damage.
PART NUMBERS
This manual does not always include the latest revision
letter when referring to UPC part numbers. Refer to the
latest Price List and Spec Sheets for the current UPC
revision letter. For example, in UPC-00x the ‘x’ indi-
cates the latest revision.
INTRODUCTION
The Unico System is a complete indoor comfort system
that includes an indoor air handling unit and small duct
system. The air handler and duct system were designed
to operate together to provide the proper airflow in every
installation. The conditioned air is supplied through a
series of 2-inch ducts as a stream of air that entrains and
mixes the room air. This process of aspiration produces a
more even temperature distribution in the room.
The Unico 'M' Modular Series air-handling units consist
of various modules that are easily latched together. The
modules can be arranged in a vertical-up-flow, vertical-
counter-flow and horizontal-flow configuration. They
can be combined as a heating-only, cooling-only, or
heating and cooling air handler unit. See Fig. 1.
All insulated Unico System modules feature closed-cell
insulation for improved sound attenuation. There is no
exposed fiberglass insulation.
TABLE OF CONTENTS
INTRODUCTION ................................................................... 1
OPTIONS ............................................................................. 2
UNPACKING ......................................................................... 2
LOCATION ............................................................................ 3
UNIT ASSEMBLY .................................................................. 4
Anti-Frost Switch Wires .................................................. 4
Fastening Modules Together .......................................... 4
EC Motor Temperature Operating Limits ......................... 4
Horizontal Installation ..................................................... 4
Vertical Installation ......................................................... 5
Control Box ..................................................................... 7
Secondary Drain Pan ..................................................... 7
MOUNTING ........................................................................... 8
Horizontal Platform Mounting ......................................... 8
Horizontal Suspended Mounting ..................................... 8
Vertical ........................................................................... 8
DUCT CONNECTIONS ........................................................ 9
Supply Plenum ............................................................. 10
Return Duct .................................................................. 10
Multiple Returns ............................................................ 10
PIPING ................................................................................ 10
Condensate Lines ........................................................ 10
Refrigerant Lines .......................................................... 11
Water Connections ....................................................... 13
Coil Cleaning ................................................................ 13
WIRING ............................................................................... 13
Ventilation Speed Mode ............................................... 14
STARTUP ............................................................................ 21
Sequence of Operation ................................................. 21
Checking Airflow ........................................................... 21
Charging the System .................................................... 23
Low Ambient Control Kit ............................................... 24
R-410A Refrigerant ............................................................. 24
Maintenance ....................................................................... 25
Module Configuration Illustrations ........................................ 26

Unico 4860 Specifications

General

Brand	Unico
Model	4860
Category	Air Handlers
Language	English

Summary

General Installation Information

Scope of Installation Manual

Defines the applicability of the installation instructions for Unico "M" Series modular air handler units.

Installer and Owner Notices

Emphasizes retaining the manual and the importance of full building insulation for economical operation.

Safety Precautions and Tips

Provides essential safety guidelines and precautions to follow before installation and startup.

Part Number Reference

Advises users to refer to the latest Price List and Spec Sheets for current UPC revision letters.

Introduction to the Unico System

Unit Options, Unpacking, and Location

System Options and Modules

Lists additional features and modules available to enhance system functionality and simplify installation.

Unpacking and Damage Inspection

Details the steps for inspecting and removing modules from shipping cartons to identify any damage.

Recommended Unit Location

Provides recommendations for selecting an optimal installation location to minimize duct runs and allow for servicing.

Unit Assembly and Mounting

Assembling Modular Units

Guides through the process of connecting modules for horizontal or vertical configurations.

Vertical Installation Procedures

Details the specific steps for assembling modules in a vertical up-flow or down-flow configuration.

Control Box Installation and Wiring

Describes how to mount the control box to the blower module and connect its wiring.

Secondary Drain Pan Requirement

Mandates the installation of a secondary drain pan to prevent water damage from condensate overflow.

Mounting Methods Overview

Covers various mounting techniques including platform, suspended, and vertical airflow installations.

Duct Connections

Supply Plenum Installation

Details the connection of supply plenums, including the use of restrictor plates for noise control.

Return Duct System Setup

Explains the installation of the return duct system, including requirements for pressure loss and bends.

Multiple Return Air Configuration

Introduces the MR module for systems requiring multiple return air paths.

Piping and Refrigerant Connections

Condensate Line Piping

Provides instructions for pitching and trapping condensate lines to ensure proper drainage.

Refrigerant Coil Connection Procedure

Covers the procedure for connecting refrigerant coils, including handling nitrogen pressure and TXV installation.

Electrical Wiring and Controls

Water Coil Connections

Details the connection of hot water and chilled water coils, including venting procedures.

Electrical Wiring and Control Box

Outlines the electrical wiring requirements and connections for the unit's control box and power supply.

Ventilation Speed Control

Explains how to configure and control the ventilation speed using the variable speed controller or thermostat.

System Startup and Airflow Verification

Sequence of Operation

Describes how the system operates in cooling, heat pump, and electric heat modes based on thermostat settings.

Airflow Measurement and Verification

Details methods for measuring and verifying proper system airflow, including static pressure and motor amperage.

Refrigerant System Charging

Provides procedures for charging the system with refrigerant, focusing on sub-cooling and superheat measurements.

Maintenance and Troubleshooting

Motorized Blower Assembly Service

Explains the steps for removing and reinstalling the motorized blower assembly for service.

Airflow Troubleshooting Guide

Lists common airflow problems, their probable causes, and recommended remedies for correction.

System Configuration Examples

Horizontal Configuration Layouts

Illustrates various horizontal single and multiple return system configurations with component part numbers.

Vertical Configuration Layouts

Shows different vertical system configurations, including module arrangements and associated parts.