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Unico M Series - User Manual

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INSTALLATION MANUAL
FOR ‘M’ SERIES
AIR HANDLER UNITS
BULLETIN 30-020
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Summary

Important Installation Guidelines

Pre-Installation Checklist

Essential steps and checks to perform before commencing the installation of the Unico System unit.

Critical Safety Warnings

Vital safety advisories concerning electrical shock, proper grounding, and safe appliance usage.

Introduction to Unico System

Installer and Owner Notification

Notification for installers and owners to retain the manual for essential information and future reference.

Scope and Precautions

General Safety and Precautions

Key safety advice covering codes, grounding, and drain pan installation for secure unit operation.

Part Numbers and Location

Information on unit part identification and optimal placement for servicing and installation efficiency.

EC Motor Operation Limits

Unit Assembly and Module Connection

Instructions on assembling modules, including flange connections and gasket compression for a secure fit.

Horizontal Installation Configuration

Specific guidance for setting up the unit modules in a horizontal airflow arrangement.

Vertical Installation Configurations

Vertical Plenum Module Usage

Details on utilizing the vertical return plenum module or conversion kit for vertical up-flow setups.

Heating-Only System Setup

Control Box Installation and Wiring

Steps for mounting and connecting the control box, including knockout removal and screw fastening.

Secondary Drain Pan Installation

Unit Mounting Methods

Horizontal Platform Mounting

Guidelines for mounting the unit horizontally on a platform, ensuring proper drain pitch.

Horizontal Suspended Mounting

Instructions for suspending the unit using chains and angle iron supports from ceiling or rafters.

Vertical Unit Mounting Considerations

Recommendations for vertical unit placement on platforms or floors due to top-heavy design.

M1218 Vertical Mounting Procedure

Ductwork Connections

Supply Plenum Adapter Installation

Connecting the main supply duct using plenum adapters for round and square ducts.

Restrictor Plate Functionality

Explains the restrictor plate's role in airflow tuning for single-speed blowers to reduce noise.

Return Air Duct System

Return Air Box and Filter Installation

Steps for installing the return air box and filter, ensuring proper fit and sealing.

Piping and Refrigerant Lines

Condensate Line Installation

Guidelines for pitching, trapping, and insulating condensate lines to prevent operational issues.

Refrigerant Line Connectivity

Instructions for connecting refrigerant lines, including sizing, filter driers, and sight glass usage.

Refrigerant System Preparation

Nitrogen Charge Release

Procedures for safely releasing nitrogen holding charge from refrigerant coils before installation.

TXV Installation Steps

Detailed steps for installing the Thermostatic Expansion Valve (TXV) for proper refrigerant flow control.

Line Set and Coil Connections

iSeries Small Tube Connection

Instructions for connecting the small tube to the distributor on iSeries coils.

Hot Water Coil Installation

Procedures for installing and connecting hot water coils, including bleeding air and freeze protection.

Electrical Wiring and Airflow Checks

Electrical Wiring Safety

Mandatory warning to disconnect power before wiring to prevent shock or death.

Airflow Verification Procedures

Methods for checking airflow using restrictors, static pressure, and velometers.

Airflow Troubleshooting and Static Pressure

Static Pressure Measurement Guide

Detailed instructions for measuring static pressure in the supply plenum using manometers.

System Charging Procedures

Refrigerant Charging and Environmental Compliance

Procedures for charging the system, adhering to environmental laws and using recovery devices.

Refrigerant Charge Verification

Sub-cooling Measurement Method

Method to measure sub-cooling for verifying correct refrigerant charge.

Superheat Measurement Method

Method to measure superheat for verifying expansion valve operation.

Unit Maintenance Procedures

Motorized Blower Assembly Removal

Steps for removing the motorized blower assembly for service or replacement.

Summary

Important Installation Guidelines

Pre-Installation Checklist

Essential steps and checks to perform before commencing the installation of the Unico System unit.

Critical Safety Warnings

Vital safety advisories concerning electrical shock, proper grounding, and safe appliance usage.

Introduction to Unico System

Installer and Owner Notification

Notification for installers and owners to retain the manual for essential information and future reference.

Scope and Precautions

General Safety and Precautions

Key safety advice covering codes, grounding, and drain pan installation for secure unit operation.

Part Numbers and Location

Information on unit part identification and optimal placement for servicing and installation efficiency.

EC Motor Operation Limits

Unit Assembly and Module Connection

Instructions on assembling modules, including flange connections and gasket compression for a secure fit.

Horizontal Installation Configuration

Specific guidance for setting up the unit modules in a horizontal airflow arrangement.

Vertical Installation Configurations

Vertical Plenum Module Usage

Details on utilizing the vertical return plenum module or conversion kit for vertical up-flow setups.

Heating-Only System Setup

Control Box Installation and Wiring

Steps for mounting and connecting the control box, including knockout removal and screw fastening.

Secondary Drain Pan Installation

Unit Mounting Methods

Horizontal Platform Mounting

Guidelines for mounting the unit horizontally on a platform, ensuring proper drain pitch.

Horizontal Suspended Mounting

Instructions for suspending the unit using chains and angle iron supports from ceiling or rafters.

Vertical Unit Mounting Considerations

Recommendations for vertical unit placement on platforms or floors due to top-heavy design.

M1218 Vertical Mounting Procedure

Ductwork Connections

Supply Plenum Adapter Installation

Connecting the main supply duct using plenum adapters for round and square ducts.

Restrictor Plate Functionality

Explains the restrictor plate's role in airflow tuning for single-speed blowers to reduce noise.

Return Air Duct System

Return Air Box and Filter Installation

Steps for installing the return air box and filter, ensuring proper fit and sealing.

Piping and Refrigerant Lines

Condensate Line Installation

Guidelines for pitching, trapping, and insulating condensate lines to prevent operational issues.

Refrigerant Line Connectivity

Instructions for connecting refrigerant lines, including sizing, filter driers, and sight glass usage.

Refrigerant System Preparation

Nitrogen Charge Release

Procedures for safely releasing nitrogen holding charge from refrigerant coils before installation.

TXV Installation Steps

Detailed steps for installing the Thermostatic Expansion Valve (TXV) for proper refrigerant flow control.

Line Set and Coil Connections

iSeries Small Tube Connection

Instructions for connecting the small tube to the distributor on iSeries coils.

Hot Water Coil Installation

Procedures for installing and connecting hot water coils, including bleeding air and freeze protection.

Electrical Wiring and Airflow Checks

Electrical Wiring Safety

Mandatory warning to disconnect power before wiring to prevent shock or death.

Airflow Verification Procedures

Methods for checking airflow using restrictors, static pressure, and velometers.

Airflow Troubleshooting and Static Pressure

Static Pressure Measurement Guide

Detailed instructions for measuring static pressure in the supply plenum using manometers.

System Charging Procedures

Refrigerant Charging and Environmental Compliance

Procedures for charging the system, adhering to environmental laws and using recovery devices.

Refrigerant Charge Verification

Sub-cooling Measurement Method

Method to measure sub-cooling for verifying correct refrigerant charge.

Superheat Measurement Method

Method to measure superheat for verifying expansion valve operation.

Unit Maintenance Procedures

Motorized Blower Assembly Removal

Steps for removing the motorized blower assembly for service or replacement.

Overview

The Unico System 'M' Series Air Handler Units are a complete indoor comfort system designed for efficient and quiet operation. This system includes an indoor air handling unit and a small duct system, engineered to work together to provide optimal airflow and temperature distribution. The conditioned air is supplied through a series of 2-inch ducts, creating an aspiration process that entrains and mixes room air for a more even temperature.

Function Description:

The Unico 'M' Series air-handling units are modular, allowing for flexible configurations as heating-only, cooling-only, or combined heating and cooling systems. They can be arranged in vertical-up-flow, vertical counter-flow, and horizontal-flow configurations. The system can even be used for ventilation-only by utilizing just the blower module. Each module is available in five sizes: 1218, 2430, 3036, 3642, and 4860.

The three basic modules are:

  • Blower Module: Includes the blower wheel, blower housing, motor (direct drive or EC motors), and electrical control box. Unico-designed and built blowers are balanced to Unico specifications.
  • Cooling Module: Contains a cooling-only refrigerant coil, a heat pump coil, or a chilled water coil.
  • Heating Module: Supplied as an empty cabinet with space for a slide-in hot water coil.

The modular design allows for easy latching together of components. For installations requiring a refrigerant coil, anti-frost switch wires must be routed to the control box during module connection. The units can be assembled either horizontally or vertically, with specific instructions for each flow arrangement. For vertical up-flow, the return air can enter through the bottom or side return opening of the cooling module (2430, 3036, 3642), with the bottom opening being preferred. The 4860 cooling module has a single return opening for both horizontal and vertical applications.

Important Technical Specifications:

  • Module Sizes: 1218, 2430, 3036, 3642, 4860.
  • EC Motor Temperature Limits:
    • Normal Operating Range: -10°F to 130°F (-76°C to 54°C) for maximum motor life.
    • Maximum Limit: 150°F (66°C), above which the motor will automatically slow down. Operation between 130°F and 150°F may reduce motor life by up to 50%, though this is often not significant for intermittent heating applications.
  • Secondary Drain Pan Dimensions (inches (mm)):
    • 1218: 24.5 x 42 (610 x 1067)
    • 2430 (2 Modules): 29.5 x 31.25 (737 x 800)
    • 2430 (3 Modules): 29.5 x 43.75 (737 x 1060)
    • 3036 (2 Modules): 34.5 x 31.5 (864 x 800)
    • 3036 (3 Modules): 34.5 x 43.75 (864 x 1111)
    • 3642 (2 Modules): 42.5 x 31.5 (1067 x 800)
    • 3642 (3 Modules): 42.5 x 43.75 (1067 x 1111)
    • 4860 (2 Modules): 42.5 x 43.75 (1067 x 1111)
    • 4860 (3 Modules): 42.5 x 54 (4067 x 1372)
    • Note: Drain fitting extends 7/8 inch (22 mm) beyond the dimension.
  • Return Air Box Opening (inches (mm)):
    • 1218: 14 3/8 x 20 1/2 (365 x 521)
    • 2430: 14 3/8 x 25 1/2 (365 x 648)
    • 3036: 14 3/8 x 30 1/2 (365 x 775)
    • 3642: 14 3/8 x 30 1/2 (365 x 775)
    • 4860: 24 3/8 x 30 1/2 (619 x 775) or 20 3/8 x 30 1/2 (518 x 775) for UPC-01-4860NC.
  • Condensate Line Connections: 3/4-inch (19mm) female pipe thread fitting for primary drain, 3/4-inch (19mm) PVC socket fitting for secondary drain. Pitch at least 1/4-inch per lineal foot (20 mm per meter).
  • Refrigerant Line and Connection Size (Standard 1 or 2-stage units):
    • Liquid line: 3/8 (9.5 mm) ODF sweat
    • Vapor line: 7/8 (22 mm) ODF sweat
  • Refrigerant Line and Connection Size ("iSeries" Var.-stage units):
    • Liquid line: 1/4 Flare (2430), 3/8 Flare (3036)
    • Vapor line: 1/2 Flare (2430), 5/8 Flare (3036)
  • Water Coil Connections: 7/8-inch (22mm) sweat OD connections.
  • Airflow (Single Speed Blowers only) @230V (Amps):
    • 4860: 1250 CFM (590 L/s) @ 4.1A, 1000 CFM (470 L/s) @ 3.5A, 800 CFM (380 L/s) @ 3.1A.
    • 3036/3642: 1000 CFM (470 L/s) @ 3.9A, 900 CFM (420 L/s) @ 3.6A, 800 CFM (380 L/s) @ 3.2A, 700 CFM (330 L/s) @ 3.0A, 600 CFM (280 L/s) @ 2.8A.
    • 2430: 600 CFM (280 L/s) @ 2.2A, 500 CFM (240 L/s) @ 2.0A, 400 CFM (190 L/s) @ 1.8A.
    • 1218: 400 CFM (190 L/s) @ 1.7A, 300 CFM (140 L/s) @ 1.5A, 200 CFM (95 L/s) @ 1.2A.
    • (Multiply by 1.1 if 208V).
  • Refrigerant Charge (Cooling Mode): Sub-cooling between 3-8°F (2-5°C). Superheat between 8-12°F (4-7°C) at indoor coil (or 15-18°F for larger capacity match-ups).

Usage Features:

  • Flexible Installation: Can be installed in attics, closets, crawlspaces, or basements. For attic installations, a platform or suspended mounting method can be used.
  • Modular Design: Allows for easy assembly and configuration (heating-only, cooling-only, or combined). Modules are latched together.
  • Sound Attenuation: All insulated modules feature closed-cell insulation for improved sound attenuation, with no exposed fiberglass.
  • Dedicated Electrical Line: Requires a dedicated electrical line for safe operation.
  • Secondary Drain Pan: MUST be installed where overflow could cause damage.
  • Minimum Clearances: 1 inch (25 mm) minimum supply plenum clearance, 5 inches (127 mm) minimum for control box cover removal, 6 inches (152 mm) minimum side clearance for service (20 inches (508 mm) for M2430C, 42 inches (1067 mm) for M4860C).
  • Return Air Duct System: Unico supplies a return duct system, but any system is acceptable if pressure loss does not exceed 0.15 inches of water (37 Pa). A minimum 90° bend in the return duct is recommended to reduce sound transmission.
  • Restrictor Plate (ST models only): Used to fine-tune airflow and eliminate objectionable outlet noise by reducing airflow when it exceeds requirements. Not to be used to adjust plenum static pressure.
  • Charging System: Follows specific procedures for refrigerant charging in cooling mode, emphasizing sub-cooling measurements. For heat pumps, refer to Bulletin 30-024.
  • Low Ambient Control Kit: Recommended for operation at outdoor temperatures below 80°F (26.6°C) to prevent coil freeze-up and maintain comfort.

Maintenance Features:

  • Easy Motor/Wheel Removal: The entire motorized blower assembly can be removed as a unit from the piping side of the unit without disconnecting modules or ducting (for 2430, 3036, 3642, 4860). For M1218, the blower assembly is removed by loosening screws and nuts from the top blower module plate.
  • Coil Cleaning: Chilled water coils should be sprayed with liquid detergent or evaporator cleaner solution and thoroughly rinsed before installation to ensure proper condensate drainage and maximum coil performance. Alternatively, allow 50 hours of break-in time.
  • Coil Removal (M1218): Hot Water Coil and Cooling Coil Modules are designed for easy removal for cleaning or replacement by disconnecting line sets and removing connection-side door panels.
  • Motor Replacement: Blower wheel can be removed from the motor shaft by loosening a set screw. Motor replacement involves removing the blower wheel first, then loosening screws fastening the motor to the inlet ring.
  • Wiring Access: Control box can be installed on the discharge side, top, or bottom of the blower cabinet, with knockouts provided for wiring.
  • Safety: All electrical wiring must comply with local codes and ordinances. Blower module controls and components are UL Standard 1995 and CAN/CSA-C22.2 No. 236 listed by ETL. 50 Hz units are CE marked and conform to Low Voltage 73/23/EEC and EMC 89/336/EEC Directives.

Unico M Series Specifications

General IconGeneral
SeriesM Series
Cooling Capacity6, 000 - 60, 000 BTU/h (depending on model)
Heating Capacity6, 000 - 60, 000 BTU/h (depending on model)
Airflow200 - 2000 CFM (depending on model)
Voltage120V or 208-230V (depending on model)
Sound Level38-48 dBA (depending on model and installation)
Dimensions (H x W x D)Varies widely depending on model; consult product brochure
WeightVaries widely depending on model; consult product brochure

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