vp002-0208 installation instructions

INSTALLATION INSTRUCTIONSMODELS:

VC2, VB2

Table of Contents

Model NonmenclatureOrder NumbersUnpacking UnitsLocating and Cutting for the OutletsLocating and Cutting for the Return AirInstalling Air HandlerInstalling the Duct SystemsInstalling OutletsRunning Drainage PipeWiring InstallationRefrigerant Lines InstallationSystem Charging and Start UpAppendix I: Hot Water Coil Kit InstallationAppendix II: Electric Heater InstallationAppendix III: VB2 Blower ChartAppendix IV: HRV/ERV Layout IllustrationAppendix V: Main Plenum LayoutAppendix VI: Assemble KoolDuct Main PlenumAppendix VII: Multiple Return Air DuctAppendix VIII: All-in-One Wiring of the 2-Ton, 2.5-Ton, 3-Ton and 4-Ton SystemsAppendix IX: All-in-One Wiring of the 5-Ton System

2 2 3 3 4 5 71214151719212325252627282930

PrefaceThese installation instructions are provided to guide fi eld technicians through the installation process and help them to understand operation and service of the VelocityPlus air handling system.

Read this manual prior to installing the VelocityPlus Air Handling System• Installation shall be made in conformance with all applicable local installation codes or the National Electrical Code, ANSI/NFPA No. 70.• Safe operating relies on complete system and correct installation. Failure to follow proper installation according to this manual can result in electrical hazard, mechanical hazard, personal injury, equipment malfunction, etc.• Detailed inspection for proper installation shall be made after installation.• Installation or repair to the VelocityPlus air handling system shall be made by qualifi ed service technicians who are familiar with safety procedures and equipment with proper tools and test equipment.

Specifi cations subject to change without notice.

Important:Before installing system, be sure to plan system layout, using the VelocityPlus Application Guide (VP011-1006). The guide will aid in a proper layout, simplifying the installation. A properly planned system will decrease installation time, lower installation costs, and increase the chances of effi cient operation.

BlowersModel Number Order NumberVB2-1824-MM2 242-040VB2-3048-MM2 482-040VB2-4860-MM2 602-040

DX CoilsModel Number Order NumberVC2-1824-MX 242-041VC2-3036-MX 362-041VC2-4248-MX 482-041VC2-4860-MX 602-041

Chilled Water CoilsModel Number Order NumberVW2-0024-M 242-042VW2-0036-M 362-042VW2-0048-M 482-042VW2-0060-M 602-042

Order Numbers

Model Nomenclature

V B 2 3048 M H 2

1824 18,000 thru 24,000 1 115-1-602430 24,000 thru 30,000 2 208/230-1-603036 30,000 thru 36,000 3 208/230-3-603048 30,000 thru 48,000 X DX Coil4248 42,000 thru 48,0004860 48,000 thru 60,000 H Horizontal only

V Vertical onlyM Multi-position

1 Series 12 Series 2 M Multi-speed

S Single speedB Blower Module V Variable speedC Cooling Coil Module Blank For coils onlyY Heat Pump Coil ModuleW Chilled Water Coil ModuleH Hot Water Coil KitE Electric Heat Kit

V Velocity Plus

Unpacking UnitsInspect the VelocityPlus air handler packaging for external damage prior to unpacking. Immediately make a claim for any damage with the carrier. It is the installer’s responsibility to inspect the unit.All VelocityPlus air handlers are fully inspected and tested before leaving our facility. Unpack and inspect the VelocityPlus air handler for damage.

1. Inspect the coil, distributor tubes, refrigeration lines, drainage fi tting, and all other components for damage.

2. Turn the blower wheel by hand to verify that it has not shifted during shipment. It should turn freely and not interfere with the blower housing.

Note: Some blower units have 3-speed motors and some are manufactured with 5-speed motors. 5-speed units are marked on the box and the electrical panels of the blower module. Any unit manufactured prior to August 2007 contains a 3-speed motor.

Locating and Cutting for the Outlets

After planning the installation using the VelocityPlus Application Guide, locate and drill or cut outlet openings in ceiling, fl oor or walls. All outlets should be located in areas of greatest heat gain or loss, i.e. above or below windows, near doors and on outside walls. When cutting holes in ceilings or walls a hole-saw and drill are the easiest to use. The following hole-saw sizes are most appropriate for installing the outlets.

3. Place short length of hanger into ¼ inch pilot hole and spin to ensure there are no obstructions.

Table 1

Figure 1

Figure 2

Figure 3

1. Before cutting holes it is best to drill a ¼ inch pilot hole where the center of the larger outlet hole will be made. All insulation above the area should be cleared in order to keep from falling through the ceiling and into the space. After drilling the pilot hole make an “L” shaped device out of a hanger or wire.

2. Bend the hanger ½ of the dimension of the hole, as shown in Table 1.

Flexduct Type & Size 2 inch 3 inchR4.2 3.5” 4.5”R8 3.75” 4.75”

Locating and Cutting for the Return Air

Locate the return air opening centrally in the structure, normally this is a hallway. Rough-in opening sizes are listed in Table 2. Note: Rough-in opening is large enough to allow equipment to be placed through them. This is helpful with attic installation.

Filter/Grill Fitting Dimensions: Rough-In Size

Rough-In Size

Return Air Filter Kit Tonnage A B241-001 2-Ton & 5-Ton 24” 14”361-001 3-Ton & 4-Ton 36” 14”

Depth for Filter: 1”

Table 2

Return air opening can be placed in either the ceiling or fl oor. Note: If cutting through plaster and lathe, mea-sure and mark the opening. Place masking tape around the outside edges of your marks (this will keep the plaster from breaking up during the cutting process). Proceed in cutting the opening according to Table 2.

The grills are sized in order to maintain the proper amount of air and the correct velocity to allow the fi lter to be effective. For attic installations, the rough-in opening allows for the equipment to be placed through and into attic.

Figure 6Return air fi lter grill.

Figure 4

Figure 5

4. Using appropriate sized hole-saw, cut outlet opening.

5. Check measurement of cut hole to ensure proper sizing, as noted in Table 1.

Installing Air HandlerWarning: If air handler is installed where condensate overfl ow could cause water damage, a secondary drain pan must be installed, i.e. in an attic.

If installing a hot water coil see Appendix 1 to install at this time.

Horizontal InstallationThe air handler consists of a blower module and a coil module. The two modules are latched together and mounted to a frame that can be either fl oor mounted on a platform or suspended from the rafters or roof trusses.

Floor Mounting

1. Use a platform to support the unit. Build the platform tall enough so that you have the height required for the J-trap and drain line pitch. The recommended pitch for the drainage pipe is ¼ inch per foot.

2. Place the platform according to installation plan and secure in place as per Figure 7.3. Place the 3/4 inch closed cell foam pad, from secondary drain kit, on platform.4. Place the secondary drain pan on the platform (if the secondary drain pan is required).5. Place the 18 rubber isolation mounts (27 in the 5-Ton kit), from the secondary drain pan kit, in the

secondary drain pan. Isolation mounts should be stacked 3 high and located in six different (nine for 5-Ton) places of the drain pan. Three of the isolation pads should be placed in each corner. The remaining six pads should be placed so they are in-line with the seam of the blower and coil module. Isolation mounts should be tall enough so that the module cabinets are above the sides of the secondary drain pan, if installed. This allows clearance for the duct connections and primary drain connection.

6. Set the blower module and the coil module individually onto the rubber isolation mounts, secure, line up and latch them together.

7. Make sure that the air handler is centered on the rubber isolation mounts.

Figure 7

Closed-Cell Foam Pad

Anti-Vibraton Pads

SECONDARY DRAIN KITS

2 - Ton 243-0293 - Ton 362-0154 - Ton 362-0155 - Ton 602-003

Suspension Mounting

1. Measure and mark roof trusses according to Figure 8 and Table 3.2. Install two U-channel tubes to roof trusses.3. Install threaded rod through U-channel and connect using washers and nuts.4. Install spring loaded isolation mounts to threaded rod as shown in Figure 8. If spring isolation

mounts are not available, the general method of isolation pads and closed cell foam, as used in the fl oor mounting can be installed below the unit on top of the upper U-channels.

5. Install a second set of threaded rods from the isolation springs to the lower U-channels connect using nuts and washers.

6. Once the two lower U-channels are positioned and level, place the two upper channels across the top.

7. Install drain pan, coil module and blower module on top of upper U-channels in the direction as specifi ed in Figure 8. Place closed cell pad onto top U-channels and place drain pan onto pad. Install vibration pads in drain pan as shown in Figure 7, prior to setting coil and blower module in pan.

8. Latch the two modules.

Figure 8

Table 3System A B

VB2/VC2 - 1824 25 40VB2/VC2 - 3036 37 40VB2/VC2 - 3048 37 40VB2/VC2 - 4860 54 42

AB

Closed Cell Foam Pad

Drain pan

Place Closed Cell TapeAround Flange

Threaded Rod to U-ChannelsAttached to Roof Trusses

Anti-Vibration Pads3 High

IsolationSpringMounts

Upper U-ChannelLower U-Channel

Threaded Rod

Connecting Supply Air Duct to Blower Connector

Installing the Duct System

Figure 9

Figure 10

Figure 11

Figure 12

1. Unbox 12 feet of 11 inch alumicore fl exduct and stretch out completely by pulling inner core until taught. Slide 11 inch aluminum fl exduct inner core over adapter.

2. Attach 48 inch cable tie around inner core, tighten using N-300 cable tie tool (or equivalent), and cut-off excess cable tie material. If not using a cable tie, the inner core must also be taped, using UL181 aluminum tape, to the adapter.

3. Pull insulation and jacket over adapter.

4. Seal using UL181 approved aluminum tape.

Before moving to the next step of installing the supply air system, please check blower to ensure it is free to spin. Spin blower wheel until seeing a hole in one of the blades of the wheel. Insert a 5/32 inch allen wrench through the hole and into the blower set screw. Check tightness of set screw on blower wheel by turning wrench clockwise.

The 11 inch duct is supplied in 12.5 foot lengths. After determining if the installation is a non-split or split type duct system, use the following chart as a reference to minimum and maximum allowable lengths. If using more than 12 feet, an 11 inch coupling kit (362-03411) should be used.

Minimum Length

Maximum Length

Blower to ADC or Split Box - 11” Duct 2 feet 35 feet

Table 4

KoolDuct Air Distribution Center (Split and Non-Split)

ADC Outlet Kit 11” Fiberglass Connector 48” Cable Tie242-0082 241010 (4) 362-050 (1) 241-009 (2)242-0083 242-0103 (6) 362-050 (1) 241-009 (2)302-0192 241010 (5) 362-050 (1) 241-009 (2)302-0193 242-0103 (8) 362-050 (1) 241-009 (2)362-0192 241010 (6) 362-050 (1) 241-009 (2)362-0193 242-0103 (9) 362-050 (1) 241-009 (2)

SADC Outlet Kit 8” or 9” Fiberglass Connector 36” Cable Tie362-0112 241010 (3) 8” - 362-052 (1) 241-005 (1)362-0113 242-0103 (5) 8” - 362-052 (1) 241-005 (1)482-0012 241010 (4) 9” - 482-051 (1) 241-005 (1)482-0013 242-0103 (6) 9” - 482-051 (1) 241-005 (1)602-0042 241010 (2.5) 8” - 362-052 (1) 241-005 (1)602-0043 242-0103 (4) 8” - 362-052 (1) 241-005 (1)

Split Box Outlet Kit 8” or 9” Fiberglass Connector * 36” & 48” Cable Tie

362-016 N/A 8” - 362-052 (2) 36” - 241-005 (2) 48” - 241-009 (2)

482-016 N/A 9” - 482-051 (2) 36” - 241-005 (2) 48” - 241-009 (2)

* At times these are manufactured using metal connectors.

Table 5

Figure 13Male portion of connector

Female portion of connector

Cable Ties Outlet

Screws

Winter shut-off cap

Clips8” or 9” Connectors

11” Connector

Split Box

ADC

Install KoolDuct Air Distribution Center (Non-Split System) and Duct

1. Unpack and check contents for damage. See Table 5 for proper contents.

Figure 19

Figure 20

Figure 17

Figure 18

Figure 15

Figure 16

2. Install spin-in onto air distribution box. Pass the smaller portion of spin-in through round holes on air distribution box wall from inside as per Figure 15. Spin the female threaded portion onto the male threaded portion until tight. as per Figure 16. Install all spin-ins in the factory cut holes.

Note: ADC boxes come with six pre-drilled 3 inch holes and eight pre-drilled 2 inch holes per ton. If for any reason, all the holes are not being used, cover extra takeoff from inside using winter caps provided, before connecting air distribution center (ADC) with main plenum. Be sure inside of ADC is free of foreign substance.

3. Place 11 inch alumicore fl exduct main plenum from blower onto 11 inch adapter, by stretching the inner core over the adapter, as per Figure 17.

4. Place 48 inch cable tie around inner core, tighten using N-300 cable tie tool (or equivalent), and cut off excess cable tie material, as per Figure 18.

5. Pull insulation and jacket and place between duct fl ange and inner core. Connect and seal main plenum to fl ange with UL181 approved aluminum tape or with tape/cable tie (applicable to round duct), as per Figure 19 and Figure 20.

Note: The ADC and secondary air distribution center (SADC) will have to be secured, either by being suspended from ceiling/rafter or supported by platform.

Figure 14

Non-Split Option System

2” or 3” Branch Runs

ADC

Main Plenum 11” Alumicore

Blower Module

Coil Module

Return Air Kit

Installing Split Box System

Figure 21

Split Box System

SADC

2” or 3” Branch Runs

SADC

Split Box

8” or 9” Alumicore

11” Alumicore Plenum

Return Air Kit

1. Place 11 inch alumicore fl exduct main plenum from blower onto 11 inch adapter, by stretching the inner core over the adapter, as per Figure 22.

2. Place 48 inch cable tie around inner core, tighten using N-300 cable tie tool (or equivalent), and cut off excess cable

tie material, as per Figure 23.

3. Pull insulation and jacket and place between duct fl ange and inner core. Connect and seal main plenum to fl ange with UL181 approved aluminum tape or with tape/cable tie (applicable to round duct).

Figure 22

Figure 23

Figure 24

Figure 25

4. Once you have the 11 inch connection, conenct the secondary plenums (either 8 inch for 3 Ton or 9 inch for 4 Ton) to the connectors on opposite die of 11 inch connector.

5. After completing 8 inch or 9 inch connections at split box, stretch ducts to the secondary air distribution boxes and connect ducts by repeating steps one to four above (or on previous page).

Minimum Length

Maximum Length

Split Box to SADC - 8” or 9” Duct 10 feet 35 feet

Table 6

Figure 26

Figure 27

Figure 28

Figure 29

Installing Flexduct to ADC or SADC

1. Slide 2” or 3” fl exduct inner core over connector fi tting. See Figure 26.

2. Attach the provided 14 inch cable tie. See Figure 27.

3. Using N-300 cable tie fasten tool (or equivalent) properly tighten cable tie.

4. Cut off excess cable tie material with N-300 cable tie fastner tool (or equivalent).

5. Pull insulation and outer jacket over inncer core. Tuck all inside outer fl ange of connector.

6. Seal, using UL181 aluminum tape, securely to outer fl ange of connector.

Figure 30

Figure 31

Prior to installing the 2” or 3” alumicore to the ADC or SADC it is necessary to open the 25 foot section of fl exduct and stretch the inner core completely. This can performed by grabbing the inner core at both ends and pulling until the inner core is taught.

Duct Size

Minimum Length

Maximum Length

2” 12 feet 35 feet3” 12 feet 65 feet

Installing Outlets

1. Pull fl exduct (including insulation and outer jacket) through opening.

2. Cut off excess fl exduct and insulation, leaving enough to attach to the outlet.

5. Attach screws and brackets to outlet. See Table 5 on Page 8 for outlet kit component list.

6. Push outlet with screws and brackets attached through opening. Brackets should spread once they are past the drywall or plaster

7. Tighten screws until outlet is fl ush to ceiling.

Figure 32

Figure 33

Figure 34

Figure 35

Figure 36

Figure 37

Figure 38

3. Attach inner core of fl exduct to fl ange of outlet with a 14 inch cable tie. Tighten and cut off excess cable tie material using N-300 cable tie tool (or equivalent). Stuff insulation and outer jacket around inner core inside of outer fl ange of outlet.

4. Seal, using UL181 aluminum tape, securely .

After installing the ducts to the ADC or SADC.

Connecting the Return Air Duct Subsystem

The following instructions apply to the return air duct subsystem provided as an accessory to the VelocityPlus air handler. All return air kits come with the following parts: 1. 1 - Coil Return Air Adapter 2. 1 - Filter/Grill Air Adapter 3. 2 - Cable Straps 4. 1 - Filter Grill 5. 1 - Filter 6. 1 - 12 foot box of Flexible Alumicore Duct

1. Install foam tape from secondary drain kit around coil return air fl ange.

2. Connect coil module transition fi tting, Item 1, to coil module with sheet metal screws and seal with UL181 approved aluminum tape.

3. Connect the return duct inner core to the coil module transition fi tting with cable tie using N-300 cable tie fasten tool (or equivalent). Seal with UL181 approved aluminum tape. Slide insulation and outer jacket over transition and seal using UL181 approved aluminum tape.

4. Install fi lter/grill adapter, Item 2, between ceiling joists above return air opening. Nail or screw into place to secure.

5. Connect return duct to the fi lter/grill transition fi tting using cable tie using N-300 cable tie fasten tool (or equivalent). Seal with UL181 approved aluminum tape. install return air fi lter/grill into wall or ceiling. Slide insulation and outer jacket over transition and seal using UL181 approved aluminum tape.

6. Install return fi lter/grill into ceiling opening made earlier in the installation.

Note: Return duct should be a minimum of six feet with one 90º turn.

Figure 39

Coil Module

1

2

3

4 5

6

Figure 40

Alternate Vertical ApplicationAttach Coil to Return Air Box

1. Apply silicone onto top fl ange of return air box. Insert return air fl anges of coil module into return air box.2. Attach blower module to coil module using latches.

Figure 41

Table 7

Running Drainage Pipe

Connect a P-trap to the ¾ inch fi tting on drain pan and secondary drain pan. Run the rest of the drain from there. A pitch of ¼ inch drop per foot on the drain line is needed.The secondary drain line should terminate where the condensation draining can be noticed to alert once primary drain fails. Proper sealing and treating means to keep drainage pipes from leaking and leak testing are strongly suggested.

Vertical Return Air Kits242-070 2-Ton362-070 3-Ton & 4-Ton602-070 5-Ton

Figure 42

Multiple Returns and ERV/HRV Option

The installer may use branch duct and Y-connectors to accommodate multiple return fi lter/grills. Also, ERV or HRV could be used in return air side (refer to Appendix III). The total pressure drop of return air duct and fi lter/grill shall not exceed 0.2 inches of water column. In order to limit sound transmission, return air duct subsys-tem, if installed, must contain at least one 90º bend, or the equivalent, between the air handler and the fi lter/grill.

Power Supply

Wiring Diagrams

Warning: By all means to avoid electric shock hazard circuit breaker or fuse must be installed to meet maximum ampere-draw requirements. Disconnect main power prior to wiring and other treatment to air handling system. Only qualifi ed electrician is allowed to conduct electrical work. Please fully comprehend wiring diagrams prior to any wiring work.

1. Field wiring indoor unit: Remove the control box cover. Run the power cord through the grommet in the control box. Connect the green wire of the power cord to “G”, black wire to the “L” and red wire to “L” of terminal block 1. Make the low voltage thermostat connections to terminal block 2. Check wiring work against factory and fi eld diagrams, as per Figure 43, 44 and 45, before engaging power supply.

2. Field wiring the outdoor condensing unit: per the manufacturer’s instructions.

Figure 43

Tonnage 1.5 - 2 Ton 2.5 - 4 Ton 4 - 5 TonPower for Blower Module 208-203/1/60 208-230/1/60 208-230/1/60Power for Element Heating 240/1/60 240/1/60 240/1/60

Table 8

WIRING INSTALLATION

Locating the Thermostat

The following should be considered when selecting a location for thermostat: Mount thermostat between four and fi ve feet above fl oor. The thermostat should be mounted on an interior wall. The thermostat should not be exposed to direct sunlight, lamps, fi replaces or other strong heat sources. The thermostat should not be mounted close to windows or doors. Do not mount the thermostat near any of the registers. Locate the thermostat where there is good natural air circulation.

Figure 44

Figure 45

For blowers:242-040602-040

For blower:482-040

Page 16

Connecting Refrigerant Line

Cautions: Prior to brazing the refrigerant line connectors purge the lines with nitrogen. Refrigerant should be prevented from being discharged into the air by all means.

It is recommended to solder refrigerant lines to prevent refrigerant leakage.If outdoor condensing unit does not have a fi lter drier in it then you must install a fi lter/drier as close to the outdoor unit as possible. This will protect the refrigerant from debris.At least one service port is needed between indoor and outdoor units.Refer to the outdoor condensing unit’s installation instructions for proper line sizing and any other information on the outdoor condensing unit.

Instructions for Installing CBBIVE Sporlan Expansion Valve to a VC2 Coil Module

1. Attach ½ inch liquid line from the evaporator to the shorter of the two stubs.2. Attach ¼ inch equalizer tube, connected to the suction line of the evaporator, to the ¼ inch stub, of the

expansion valve.3. Connect the liquid line from the condenser to the longer of the two stubs. The stub has “IN” marked on the

body of the valve just below it.4. Connect the suction line of the condenser to the suction connection at the evaporator.5. Mount bulb of expansion valve, using the band included in the kit, at about four o’clock on the suction line

prior to (up-stream) the connection of the equalization tube.6. Insulate bulb and suction line.

Cap with adjustment stemCap with adjustment stem

Marked “IN” on the wall of the valve body.Marked “IN” on the wall of the valve body.

Connect to ½ inch liquid line from evaporator

Connect to ½ inch liquid line from evaporator

Connect to liquid line from condenserConnect to liquid line from condenser

Connect the ¼ inch equalization tube, connected to the suction line coming from the evaporator

Connect the ¼ inch equalization tube, connected to the suction line coming from the evaporator

Figure 46

Adjustments:Adjustments can be made by removing the cap at the bottom of the valve exposing the adjustment stem.Turning the stem counter-clockwise reduces the superheat.Turning the stem clockwise increases superheat.

Refrigerant Lines Installation

INSTRUCTIONS FOR INSTALLING DANFOSS EXPANSION VALVE

1. Attach 1/2 inch liquid line from evaporator to 1/2 inch stub coming out the side.2. Attach 1/4 inch equalizer tube, connected to the suction line of the evaporator, to the 1/4 inch stub of expansion valve.3. Connect the liquid line from the condenser to the stub on the bottom of the expansion valve.4. Connect suction line of condenser to the suction connection of the evaporator.5. Mount bulb of expansion valve, using the band included in the kit, at about four o’clock on the suction line prior to up-stream the connection of the equalization tube.6. Insulate bulb and suction line.

Adjustments: Adjustments can be made by removing cap on the side of valve using a 5/32 inch allen wrench. Once removed turn clockwise using 5/32 inch allen wrench to increase the superheat. Turn counter clockwise to decrease superheat.

Figure 47

Installing the Outdoor Condensing Unit

Per the manufacturer’s instruction.

Bulb attached to suction line

Connect to coil

Connect to 1/4 inch equalization tube

Superheat adjustment

Connect to liquid line

System Charging and Start Up

Before release to operation, the following should be checked: Indoor and outdoor units are located properly and fi rmly mounted. There is no interference between fan wheel and fan housing. Duct and other duct components are securely connected and properly sealed. Refrigeration lines are connected properly and securely. Refrigerant lines do not leak. The system is wired according to installation instructions, national and local codes. There is no blockage at the return air intake or around the outdoor unit. Drainage pipe for the unit has been installed. Return air intake, discharge air outlets and dampers are wide open. Thermostat is located, connected and set. Checking Air Flow

Caution: Do not operate blower with free discharge or low static pressure (below 1 inch water column (250 pa)) to prevent motor from overloading

After the system is installed and before charging system, check for proper airfl ow. Record the return static pressure, the plenum static pressure, and the motor amperage. With this information, the amount of airfl ow can be determined.As a recommended further check on airfl ow, use a velometer to measure the airfl ow from each outlet. The most convenient instrument to use is a hand held vane type velocity meter that fi ts directly over the outlet or digital anemometer that measures the FPM and can be converted to CFM by the following formulas: 2 inches FPM x 0.022 = CFM 3 inches FPM x 0.0415 = CFM

By measuring and totaling the airfl ow of all outlets the total airfl ow of the system can be closely approximated and provide a crosscheck for the airfl ow determined from the motor amperage and static pressure measurements with the blower charts in this installation instruction.

Check Static Pressure: Measure the external static pressure (see the following section) in the supply plenum at least 18 inches from the unit and verify that it is within the allowable range.In a 2” system, the supply system static pressure should be 1.2 to 1.4 inches of water column. In a 3” system, the supply system static pressure should be 0.9 to 1.1 inches of water column.It is not necessary to measure the return duct static pressure unless it was fi eld fabricated. The maximum return static pressure (including fi lters) should be 0.2 inches of water column. If it is greater than 0.2 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 water column, and the return system pressure drop is 0.25 inches water column, the total static pressure drop is: 1.6 + 0.25 = 1.85 inches water column. In this case the static pressure is too high. Lowering the blower speed will decrease the static pressure and lower any air noise.

Check Motor Amperage: Remove the control box cover and measure the current with an amp meter. Refer to blower chart on page 25. The static pressure and amp draw will give you the total CFM of the system.

Figure 50

Checking the Charge

With the fan set to “AUTO” and thermal mode set to “COOLING”, the air handler fan, outdoor condensingunit fan and compressor should now be running. Raise the thermostat temperature setting until the system turns off. The air handler fan should not be running. The condensing unit fan and compressor should not be running. Normally outdoor unit is pre charged for 25 feet of refrigerant pipe. If both liquid and gas refrigerant lines get to be longer or shorter than 25 feet the refrigerant charge needs to be adjusted per condenser manufacturer’s instructions. Measure superheat using gauge and thermocouple per illustration:

The TEV is adjustable, adjust superheat to 10° F to 12° F when the ambient temperature around outdoorunit is in range from 65° F to 85° F; to 7° F to 9° F when ambient temperature is in range from 85° F to105° F; to 4° F to 6° F when ambient temperature is above 105°F. After about 30 minutes of systemrunning in COOLING mode, the air temperature difference across the coil should be in range from 20° Fto 30° F.

Check Outlet Airfl ow: Measure and record the airfl ow from each outlet with a turbo meter or anemometer. The sum is the total airfl ow; this can be compared to the air fl ow indicated by the amperage on the blower chart. A signifi cant difference could indicate duct leakage.

How to Measure Static Pressure: Measure the supply plenum static pressure at least 18 inches from the unit. A distance of between two and three feet is best. Use an inclined manometer capable of reading at least 2.5 inches of water column. Be sure to zero the scale. A magnahelic gauge that measures up to at least 2.5 inches of water column may also be used.Use a metal tube, typically ¼ inch diameter, to measure the static pressure. Determine placement, then 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 (25 mm) so that the tip of the tube is fl ush to inside wall of the duct and perpendicular to the air stream, and tape the tube in place using UL181 aluminum tape. A pitot tube can also be used (see Figure 49). Attach the metal tube to the manometer using a rubber hose (usually supplied with the manometer). Record the pressure. The reading will be in error if the tube is angled toward the air stream.

Figure 48 Figure 49

Appendix 1: Hot Water Coil Kit Installation

This installation is much easier if performed prior to installing system.

1. Remove screws from side cover plate of coil module, discard plate.

2. Cut away and discard insulation behind plate.

3. Remove screws from top of coil module and remove top.

4. Remove screws on side holding evaporator coil in place (only remove one side along top).

5. Place hot water coil with connection and through opening from inside cabinet.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

11. Connect water pipe. Cut water inlet and outlet pipes. Remove any sharp burs.

Leave pipe segments around connection points clear of any fl ammable material. Wrap pipe with wet rags before soldering. Connect and solder water supply and return pipes (water valve if available should be installed). After pipes cools down slit the insulation sleeve and place it around the pipes. Twist insulation sleeves through the hole to make sure they are well sealed.

12. Prepare hot water coil and conduct trial operation. Flush hot water coil with water for one minute. Keep water running through hot water coil, pass screwdriver through rubber cover of vent-valve, leave vent-valve open for 20 to 60 seconds to vent air. Make sure vent hose is tightened onto coil header towards inside of drain pan. In same way, check if drain-valve works well and drain hose is tightened onto coil header towards inside of drain pan.

6. Align end brackets of hot water coil so that the screw holes in the bracket line up with the holes in the casing.

7. Install screws through cabinet into brackets on both sides.

8. Install new cover plates around water line connections. Secure with existing screws.

9. Replace screws from vaporator brackets.

10. Re-install top.

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Appendix II: Electric Heater Installation

1. Unpack and check for damage

3. Slide and insert heater assembly into coil module.

4. Prepare line power and circuit breaker for heater.

5. Wire control boxes and blower module and heater assembly.

2. Remove cover plate

Screws can be used to secure heater.

Put screws in holes of both cabinet and heater fl ange to fasten heater onto coil module.

Design line voltage: 240/1/60Amp ratings at 240/1/60: 5KW-21A, 7.5KW-32A, 10KW-42A, 12.5KW-53A, 15KW-63A,17.5KW-73A, 20KW-84AIf voltage other than 240V is used, current and KW ratings will change accordinglyMaximum ampere and wire sizing (copper, no more than 3 conductors in a raceway) gaugeguidance (for 75C per NEC 1999 Table 310-16, 125% wire sizing for 50KW or below): 40A-8AWG, 52A-6AWG, 68A-4AWG, 80A-3AWG, 92A-2AWG, 104A-1AWGDedicated right size of circuit breaker must be used to protect circuit per NEC and local codes.

Part NumberKW & Power for Residential Use

Rated Current

(A)

Minimum Airfl ow (CFM)

2-Ton241-045-5.0 5.0 KW, 240/1/60 21 260241-045-7.5 7.5 KW, 240/1/60 32 390241-045-10.0 10.0 KW, 240/1/60 42 520

2.5-Ton and 3-Ton361-045-7.5 7.5 KW, 240/1/60 32 390361-045-10.0 10.0 KW, 240/1/60 42 520361-045-12.5 12.5 KW, 240/1/60 52 650361-045-15.0 15.0 KW, 240/1/60 62.5 780

4-Ton361-045-10.0 10.0 KW, 240/1/60 42 520361-045-12.5 12.5 KW, 240/1/60 52 650361-045-15.0 15.0 KW, 240/1/60 62.5 780481-045-17.5 17.5 KW, 240/1/60 73 900

5-Ton601-045-12.5 12.5 KW, 240/1/60 52 650601-045-15.0 15.0 KW, 240/1/60 62.5 780601-045-17.5 17.5 KW, 240/1/60 73 900601-045-20.0 20.0 KW, 240/1/60 84 1040

Wiring diagram of slide-in electric heater:

Part Number KW & Power for Residential Use

Rated Current

(A)

Minimum Airfl ow (CFM)

242-045-7 7.5 KW, 240/1/60 32 390242-045-10 10 KW, 240/1/60 42 520362-045-7 7.5 KW, 240/1/60 32 390362-045-10 10 KW, 240/1/60 42 520362-045-12 12.5 KW, 240/1/60 52 650362-045-15 15 KW, 240/1/60 62.5 780

Next generation Electric Heaters. Replaces prior generation as inventory depletes.

Appendix IV: HRV/ERV Layout Illustration

Notes: Installation of HRV/ERV

and duct sizing are per HRV/ERV OEM instructions.

Fans shall be inter-linked between HV indoor unit and HRV/ERV unit.

Return air grill shall be installed from exhaust air grill no closer than 12’ away.

2-1 merge and other duct fi ttings may not be supplied with HV systems or HRV/ERV.

ESP 1.5 - 2 Ton 2.5 - 3 Ton 2.5 - 4 Ton 5 TonInches WC High Med Low High Med Low High Med Low High Med Low

0.5 830 716 597 950 792 649 1495 1112 914 1740 1658 14050.6 818 705 588 940 783 642 1480 1101 905 1720 1638 13880.7 810 698 582 931 776 636 1465 1096 900 1696 1615 13690.8 845 728 607 921 767 629 1456 1092 895 1688 1607 13620.9 768 662 552 911 760 623 1442 1081 890 1671 1591 13491.0 740 638 532 902 752 616 1429 1074 883 1661 1582 13411.1 730 629 524 893 745 610 1443 1063 874 1645 1566 13271.2 720 621 517 885 737 604 1387 1060 871 1581 1506 12761.3 692 597 497 876 730 598 1373 1050 862 1572 1497 12691.4 685 591 492 867 723 592 1354 1032 849 1550 1477 12511.5 644 555 463 859 716 586 1332 1028 837 1520 1448 12271.6 638 550 458 847 706 578 1314 1023 831 1499 1428 12101.7 631 544 454 835 696 570 1236 1013 795 1478 1408 11931.8 625 539 449 824 686 563 1224 1003 787 1458 1388 11771.9 619 534 445 812 677 555 1212 993 779 1438 1369 11602.0 613 528 440 801 667 547 1154 910 730 1418 1350 1144

Appendix III: VB2 Blower Chart

Appendix V: Main Plenum Layout Basement Application

Hexagonal Plenum

Rectangular Plenum

Cap900034

Plenums are 4 feet in length

Holes cut on jobsite using hole-saw in reverse.

No more than 4 holes per section (2 holes peer side).

Duct connectors must be attached prior to connecting each section together.

Holes should be at least 12 inches apart.

Plenum900035

Elbows available for loop systems900036

Cap241-0179 or 361-0139

Elbows available for loop systems241-0177 or 361-0137

Plenum241-0178 or361-0138

Plenums are 4 feet in length

Holes cut on jobsite using hole-saw in reverse.

No more than 2 holes per section if cutting from top. No more than 4 holes per section if cutting from side (2 per side).

Duct connectors must be attached prior to connecting each section together.

Holes should be at least 12 inches apart.

Requires use of a blower adapter242-048 (for VB2-1824)362-048 (for all other models)

Requires use of a blower adapter900037 for all models

Appendix VI: Assemble KoolDuct Main Plenum: Rectangular and Hexagonal

1. Unpack kit box.

Unpack kit box and check plenum for damage.Rectangular plenum comes 2 per box.Hexagonal plenum comes 1 per box.

2. Apply silicone.

Apply PAL silicone (21612) at connection surfaces evenly.

3. Align duct.

Support may be needed to help align the plenums.

4. Attach tiger connector.

Attach one tiger connector at each middle side surface and make sure connector fi ts fi rmly across each plenum side. A minimum of two connectorsis needed. Always place tiger clips on opposing sides to ensure regidity.

5. Seal seam and secure plenum.

Press connector until fl ush with plenum. Check

Appendix VII: Multiple Return Air Duct

Number of Branches 2 Ton 3 Ton 4 Ton 5 Ton2 11 inch 12 inch 12 inch 14 inch3 N/A 11 inch 11 inch N/A4 N/A N/A 9 inch 11 inch6 N/A N/A N/A 9 inch

Branch runs should not extend more than 35 feet.

Appendix VIII: All-in-One Wiring of 2-Ton, 2.5-Ton, 3-Ton and 4-Ton Systems

Appendix IX: All-in-One Wiring of 5-Ton System

ESPI-TECH, LLC680 Crown Industrial Court, Unit HChesterfi eld, MO 63005Tel: (636) 536-9446 Fax: (636) 536-9441

VP 002-0208 Revised 02-20-08

vp002-0208 installation instructions

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