Bulletin 40-60 (October 2004)

UNICHILLER RC DESIGN MANUAL

Specifications subject to change at the discretion of the manufacturer.

Bulletin 40-60 (October 2004) Page 2

TABLE OF CONTENTS TABLE OF CONTENTS........................................................................................................ 2 GENERAL ............................................................................................................................ 3 SCOPE ................................................................................................................................. 3 GENERAL PRECAUTIONS AND SAFETY TIPS ................................................................. 3 INTRODUCTION .................................................................................................................. 4 APPLICATIONS ................................................................................................................... 4 COMPARISON: UNICHILLER VERSUS CONDENSING UNIT............................................ 4 BENEFITS ............................................................................................................................ 4 PART NUMBERING INDEX ................................................................................................. 5 SPECIFICATIONS................................................................................................................ 5 Operating Range ............................................................................................................................... 6 Chiller Dimensions ........................................................................................................................... 6 Figure 1: Chiller Dimensions................................................................................................. 6 SAFETY COMPONENTS ..................................................................................................... 7 LOCATION ........................................................................................................................... 7 SIZING.................................................................................................................................. 8 PIPING SYSTEM PRESSURE DROP CALCULATIONS AND PIPE SIZING....................... 9 PUMP PERFORMANCE CURVE....................................................................................... 14 EXAMPLES OF PRESSURE DROP CALCULATIONS AND PIPE SIZING ....................... 15 DETERMINE PROPYLENE GLYCOL PERCENTAGE....................................................... 20 How to put propylene glycol in the system .................................................................................... 20 EFFECT OF PROPYLENE GLYCOL ON AIR HANDLERS AND UNICHILLER................. 20 STORAGE TANK ............................................................................................................... 21 PIPING SCHEMATICS (PARALLEL PIPING) .................................................................... 23 PIPING SCHEMATICS (PRIMARY-SECONDARY PIPING) .............................................. 27 WIRING .............................................................................................................................. 30 Ladder Wiring Schematic ............................................................................................................... 30 Pictorial Wiring Diagram................................................................................................................ 31 STARTUP........................................................................................................................... 32 Sequence of Operation.................................................................................................................... 32 Digital Temperature Controller Operation...................................................................................... 32 SINGLE CHILLER SYSTEMS ............................................................................................ 33 MULTIPLE CHILLER SYSTEMS........................................................................................ 35 Two Chiller Systems without Stage Controller (Special Case) ...................................................... 35 Two or More Chiller Systems with Stage Controller ..................................................................... 35 RE-LOCATING SELECTOR SWITCH................................................................................ 36 LOW AMBIENT OPERATION ............................................................................................ 37 TROUBLESHOOTING........................................................................................................ 38 SERVICEABILITY .............................................................................................................. 39 MAINTENANCE ................................................................................................................. 39 REFERENCES ................................................................................................................... 40

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GENERAL The following information is to help the installer save time, provide the best possible installation and ensure continuous trouble-free operation. SCOPE This manual applies to Unichiller self-contained reverse cycle chillers and cooling-only chillers. Both referred to as a chiller unless there is a special instruction. Then the terms reverse-cycle or cooling-only will be used. The Unichiller is designed to match all Unico System chilled water coils. It can also be used with conventional air handlers of appropriate size or wall-hung or ceilinghung chilled water fan coil units. GENERAL PRECAUTIONS AND SAFETY TIPS

!
!

Before operating, be sure the unit is properly grounded to prevent injury or death from electrical shock! Disconnect electrical supply before wiring unit to prevent injury or death from electrical shock! Do not handle the top half of the scroll compressor as it operates at a temperature high enough to cause serious injury.

Do not operate this system with water alone. A minimum of 10% propylene glycol is essential for proper operation. Do not use any liquid solution other than the solution of water and propylene glycol (mixed in accordance with Table 9 of this manual) in the piping system. Pump must be primed (free of air and suction pipe full of liquid) before starting. If pump is run dry, rotating parts will seize and mechanical seal will be damaged. All electrical wiring should be in accordance with the latest edition of the National Electric Code and all local codes and regulations. The unit is safety certified to UL 1995, CAN/CSA STD C22.2 NO. 236 and listed with ETL. All piping must be in accordance with all local codes and ordinances. 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. These units are designed to operate exclusively with R-22 in a self-contained, pre-charged refrigerant system. Do not access the closed refrigerant system for any reason other than after-sale, after installation component replacement. Such service is to be conducted by qualified personnel only. All units are inspected prior to shipping and are carefully packaged in cartons. Inspect all cartons prior to unpacking. Remove the unit from package and inspect for any visible signs of concealed damage. Notify carrier of any damage. Clean the cabinet air filters regularly. The filters clean the air cooling the circulation pump.

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INTRODUCTION The Unichiller is a self-contained, outdoor, air-cooled liquid chiller or reverse-cycle liquid chiller. It uses R-22 refrigerant as a working fluid to cool or heat water, which, in addition to being safer for the environment, is more energy efficient than conventional air conditioning. It also can provide zoned cooling or heating with just a single unit, so you can use multiple air handlers to provide cooling or heating only to those areas in need of it at any given time. APPLICATIONS Unichillers can be used in residential, light commercial and some industrial applications. The heating mode of the Unichiller is suitable for radiant floor heating and snow melt in addition to air heating applications. COMPARISON: UNICHILLER VERSUS CONDENSING UNIT Unichillers can be undersized up to 20% if there is more than one zone and if not all the zones will be operating at the same time. A Manual N (load diversification) calculation can also be done to see if the chillers can be undersized further. Condensing units have to be sized exactly to match the air handling unit. Unichillers are designed for partial load (less than design) conditions. Therefore, zoning is possible and easy with Unichillers. Condensing units are designed only for full load conditions making zoning very hard. The Unichillers are pre-charged and self-contained so unless breaking into the refrigerant lines is necessary (see Troubleshooting section), there is no need for a refrigeration license. For a condensing unit, a refrigeration license is mandatory for both installation and service. Remote locations up to 300 ft (91 m) away are possible with Unichillers as long as the water lines are sized in accordance with this manual. However, a condensing unit has to be close to the house, typically less than 75 ft (23 m). Refer to individual condenser manufacturer for exact limitations. The Unichiller is quieter than a typical outdoor condensing unit. It has two fans compared to one fan on most condensing units. BENEFITS Unichiller is a self-contained and pre-charged unit. Therefore, there is no refrigerant handling during installation. The contractor connects only the water piping and electrical power. There is no refrigerant inside the house. It is easy to zone because there is no freeze-up problems caused by partial load conditions. The Unichiller operates based only on the water temperature sensed by the temperature controller inside the unit (unless the installer made modifications to the controls). Piping is simple and cost effective. The Unichiller is quieter than a typical condensing unit. It can be placed at a remote location as long as the piping is sized in accordance with this manual. There is no need for a large area around the unit (see Figure 2 for clearances). It is possible to bank multiple units for larger loads.

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PART NUMBERING INDEX The following chart represents the part numbering system of the chillers.
UCH - XXX - # - N - P Product Line UCH: Unichiller UCHR: Reverse Cycle Unichiller Size 036: 3-ton unit 060: 5-ton unit Revision Code Electrical Designation 1: 1 phase, 208/230 V, 60 Hz 2: 3 phase, 230 V, 60 Hz 3: 3 phase, 440 V, 60 Hz 6: 1 phase, 220 V, 50 Hz 7: 3 phase, 380 V, 50 Hz Additional Options

SPECIFICATIONS
Min. Circuit Ampacity UCHR-036-1-1-P 36,000 [10.6] 29.1 UCHR-060-1-1-P 60,000 [17.6] 41.7 69 UCHR-036-1-6-P 36,000 [10.6] 25.5 UCHR-060-1-7-P 60,000 [17.6] 16.6 * Sound measurement taken at 3feet from the front of the unit. Model Number Pump Data Max Flow Rate, GPM [L/s] Head Press at Min. Flow Rate*, ft. water [kPa] Supply Water Temp, F [C] Nominal Capacity, Btu/hr [kW] Electrical Data Sound level*, dB Max. Fuse/ Circuit Breaker 45 60 40 25 Voltage 208/230 220 380 Hz 60 50 Phase Amps @230V 19 25.5 22.5 14.7 Refrigerant Type Charge, lb. [kg] 5.1 [2.3] 7.9 [3.6] 5.1 [2.3] 7.9 [3.6] Approx. Shipping Weight, lb [kg] 310 [141] 340 [154] 310 [141] 340 [154]

1 3

R-22

Other Data Approx. Chiller Volume, Gal. [L] Minimum Expansion Tank Size**, Gal. [L]

Model Number

Min Req. Flow Rate, GPM [L/s]

Pump Size, HP [W]

Pump Speed, RPM

Min. System Volume, Gal. [L]

UCHR-036-1-1-P 7.2 [0.6] 50 [149.5] [560] UCHR-060-1-1-P 12 [0.9] 14 45 [134.5] 1-1/3 [1007] [0.9] UCHR-036-1-6-P 7.2 [0.6] 50 [149.5] [560] UCHR-060-1-7-P 12 [0.9] 45 [134.5] 1-1/3 [1007] *Evaporator pressure drop is included. ** Not included, field installed.

3450 44 [6.7] 2850 25 [95] 1.0 [3.8] 1.0 [3.8]

COOLING PERFORMANCE
Performance*** Model UCHR-036-1-1-P (60 Hz) UCHR-036-1-6-P (50 Hz) Outside Capacity Power Input Efficiency Capacity Power Input Efficiency Temperature F [C] Btu/hr [kW] W EER [COP] Btu/hr [kW] W EER [COP] 82 27.8 36,200 10.6 3300 11.0 3.2 32,400 9.5 2700 12.0 3.5 95 35.0 33,900 9.9 3820 8.9 2.6 30,300 8.9 3140 9.6 2.8 100 37.8 33,000 9.7 4040 8.2 2.4 29,400 8.6 3330 8.8 2.6 105 40.6 32,100 9.4 4270 7.5 2.2 28,500 8.4 3540 8.1 2.4 110 43.3 31,100 9.1 4520 6.9 2.0 27,500 8.1 3770 7.3 2.1 *** Based on compressor data. At 44F leaving water temperature and minimum required flow rate. Performance*** Model UCHR-060-1-1-P (60 Hz) UCHR-060-1-7-P (50 Hz) Outside Capacity Power Input Efficiency Capacity Power Input Efficiency Temperature F [C] Btu/hr [kW] W EER [COP] Btu/hr [kW] W EER [COP] 82 27.8 56,700 16.6 4790 11.8 3.5 54,000 15.8 4120 13.1 3.8 95 35.0 52,600 15.4 5460 9.6 2.8 50,300 14.7 4830 10.4 3.0 100 37.8 50,800 14.9 5750 8.8 2.6 48,700 14.3 5130 9.5 2.8 105 40.6 48,900 14.3 6060 8.1 2.4 47,000 13.8 5460 8.6 2.5 110 43.3 46,800 13.7 6380 7.3 2.1 45,200 13.2 5800 7.8 2.3 *** Based on compressor data. At 44F leaving water temperature and minimum required flow rate.

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HEATING PERFORMANCE
Performance*** Model UCHR-036-1-1-P (60 Hz) UCHR-036-1-6-P (50 Hz) Outside Capacity Power Input Efficiency Capacity Power Input Efficiency Temperature F [C] Btu/hr [kW] W EER [COP] Btu/hr [kW] W EER [COP] 10 -12.2 25,800 7.6 3310 7.8 2.3 22,400 6.6 2960 7.6 2.2 17 -8.3 27,100 7.9 3320 8.2 2.4 23,600 6.9 2950 8.0 2.3 33 0.6 30,900 9.1 3330 9.3 2.7 27,100 7.9 2930 9.2 2.7 47 8.3 35,300 10.3 3340 10.6 3.1 31,500 9.2 2900 10.9 3.2 55 12.8 38,600 11.3 3340 11.6 3.4 34,800 10.2 2890 12.0 3.5 65 18.3 43,800 12.8 3340 13.1 3.8 40,000 11.7 2870 13.9 4.1 *** Based on compressor data. At 120F leaving water temperature and minimum required flow rate. Performance*** Model UCHR-060-1-1-P (60 Hz) UCHR-060-1-7-P (50 Hz) Outside Capacity Power Input Efficiency Capacity Power Input Efficiency Temperature F C Btu/hr [kW] W EER [COP] Btu/hr [kW] W EER [COP] 10 -12.2 36,100 10.6 4630 7.7 2.3 34,700 10.2 4520 7.7 2.3 17 -8.3 38,100 11.2 4660 8.2 2.4 36,700 10.8 4510 8.1 2.4 33 0.6 43,900 12.9 4750 9.2 2.7 42,200 12.4 4480 9.4 2.8 47 8.3 50,900 14.9 4830 10.5 3.1 48,800 14.3 4460 10.9 3.2 55 12.8 56,000 16.4 4880 11.5 3.4 53,500 15.7 4450 12.0 3.5 65 18.3 63,700 18.7 4940 12.9 3.8 60,800 17.8 4450 13.7 4.0 *** Based on compressor data. At 120F leaving water temperature and minimum required flow rate.

Operating Range
Normal Operating Range Water Temperature Range COOLING 20* to 115F (-7 to 46C) outside temperature 38 to 60F (3 to 16C) HEATING 10 to 70F (-10 to 21C) outside temperature Up to 125F (52C)

* Use a low ambient kit and replace the low pressure switch with a 20-40 psig switch when operated below 65F (18C).

Chiller Dimensions Figure 1 shows the overall dimensions of the Unichillers. All sizes and models have the same dimensions.
18.25 [464]

37.5 [953]

45.75 [1162]

4.9 [124]

1-inch MPT

33.4 [849] 1.25-inch Knockout 1.5 [38] 2.1 [53]

7.75 [197]

2.00 [51] 11.6 [295] 3.25 [83] 13.1 [333] 3.75 [95]

1-inch MPT

Figure 1: Chiller Dimensions

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SAFETY COMPONENTS Flow Switch: There is a flow switch that is activated if there is an interruption in the liquid solution flow. It shuts the unit down, if activated. High Pressure Switch: High pressure switch opens at 400 psig and resets at 300 psig. It is used both in heating and cooling modes. Low Pressure Switch: Low pressure switch opens at 40 psig and resets at 80 psig. It is used only in the cooling mode.

Five-Minute Delay on Break Timer: It activates every time the compressor shuts down.

LOCATION When selecting a location for the chiller, keep the following in mind: The minimum required clearances are 24 inches on the service access side, 12 inches for air inlets on all sides and 60 inches for air discharge side (see Figure 2).
TOP VIEW FRONT VIEW
12 inches (0.3 m) 12 inches (0.3 m)
air inlet air inlet 6 inches (0.15 m) minimum or 24 inches (0.6 m) for service service access side
12 inches max (0.3 m)

Overhang

24 inches (0.6 m)

60 inches (1.5 m)
air discharge

shrubs or porous wall

Maximum height of wall is 4.5 ft (1.4 m)

IL00349.CNV

Figure 2: Unichiller Clearances

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The chiller is an outdoor unit and must be located outdoors. It cannot be connected to condenser air with ductwork, or placed inside a room. Locate the chiller cabinet at a level sufficiently above grade to prevent ground water from entering. In areas with heavy snow, further elevation may be necessary. Installing unit in a pit will degrade performance. In some cases, use of air deflectors is necessary. Contact factory for specific recommendations. When installing near salt water, the best location is on the shore side of the building. To improve longevity, coat the fins with Adsil fin coating or equal.

* Adsil is a registered trademark of Adsil, Palm Coast, FL.

SIZING The first step in sizing the Unichillers is calculating heat gain/loss of the house. Then the designer must consider the different zones in the house. The Unichillers must be selected to handle the heat gain results for cooling. Typically, if there is more than one zone in the house and not all the zones will be operating at the same time, then the Unichillers can be undersized by as much as 20% (only when there is more than one chiller) and piped in parallel. Piping the Unichillers in parallel will ensure that if one chiller is not satisfying the load, then another unit can turn on to help with the load. 20% is only a rule of thumb. In order to be completely accurate, a Manual N (load diversification) must be done. Manual N will show the designer how the load changes during the day so that the designer can calculate the best combination of units that will handle the load at the worst case scenario.

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PIPING SYSTEM PRESSURE DROP CALCULATIONS AND PIPE SIZING Unichillers have pumps capable of moving the minimum liquid solution flow at 55 ft of water (164 kPa) and 90 feet of water (269 kPa) for the 3-ton and 5-ton, respectively. The total pressure drop for the piping system must be calculated to determine whether the proposed piping system will deliver the amount of liquid solution required. If the total pressure drop of the system exceeds pumps capability, then increase the pipe size and recalculate the total pressure drop. The pressure drop for a piping system can be calculated by adding the following pressure drops: Piping pressure drops Fitting pressure drops Component pressure drops (valves, etc.) Chiller pressure drops Air handler pressure drops

Table 1, Unichiller System Data, determines the pressure drop of the chiller including the heat exchanger, strainer, and internal pipe and fittings. Table 2, Unico Air Handler Flow Rates and Pressure Drops, lists the pressure drops of the Unico Air Handlers. Table 3, Fitting Loss in Equivalent Feet of Straight Pipe, provides the equivalent feet of straight pipe for fittings. Tables 4, 5, 6, and 7, Pressure Losses of Composite Pipe (Kitec), Copper, PEX, PVC, respectively, provide piping pressure drops for various piping types (listed in feet of water per 100 feet). There is an easy and fast rule of thumb method to calculate the total pressure drop through a piping system rather than adding the pressure drops for the pipe, individual fittings, and piping components. The rule of thumb method is to measure the installed length of pipe and then multiply the total length by 150% (example: 120 feet of installed pipe x 150% = 180 equivalent feet of pipe). Use the rule of thumb method only for estimation purposes.
Table 1: Unichiller System Data Model Internal Chiller Pressure Loss, ft water (kPa) UCHR-036-1-1-P UCHR-036-1-6-P UCHR-060-1-1-P UCHR-060-1-7-P 10 [29.9] 10 [29.9]
2

45 [134.5]

45 [134.5]

Table 2: Unico Air Handler Flow Rates and Pressure Drops Flow Rate M1218 MC2430W MC3660W GPM (L/s) ft water (kPa) ft water (kPa) ft water (kPa) 3 (0.19) 4 (0.25) 5 (0.32) 6 (0.38) 7 (0.44) 8 (0.50) 9 (0.57) 10 (0.63) 1.8 (5.37) 3.4 (10.15) 5.3 (15.83) 7.7 (22.99) 10.4 (31.05) 13.5 (40.31) 16.9 (50.46) 20.7 (61.81) 1.8 (5.4) 3.5 (10.5) 5.3 (15.8) 7.4 (22.1) 9.8 (29.3) 12.6 (37.7) 15.7 (46.9) 19.2 (57.4) 1.1 (3.3) 2.0 (6.0) 3.6 (10.8) 4.8 (14.3) 6.8 (20.3) 8.1 (24.2) 10.9(32.6) 12.2(36.4)

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* At 45F entering water temperature. Table 3: Fitting Loss in Equivalent Feet of Straight Pipe (based on 4 fps) Male Male Size of Pipe Adapters* Adapters** (forward) (reverse) in (mm) 1/2 (12) 3/4 (20) 1 (25) ft (m) 2.0 (0.6) 2.0 (0.6) 2.0 (0.6) ft (m) 3.0 (0.91) 3.0 (0.91) 3.0 (0.91) 90 Deg. Elbow ft (m) 7.5 (2.3) 8.5 (2.6) 9.0 (2.7) Tee Run ft (m) 2.5 (0.67) 2.5 (0.67) 2.5 (0.67)
3

Tee Branch ft (m) 8.0 (2.4) 10.5 (3.2) 11.0 (3.4)

Copper Adapter ft (m) 2.0 (0.6) 1.5 (0.46) 1.5 (0.46)

* Forward flow directions: standard schedule composite pipe to Kitec. ** Reverse flow directions: Kitec to standard schedule composite pipe. Table 4: Composite Pipe (Kitec) Pressure Losses Pressure Drop, ft water/100 ft (kPa/m) Flow Rate, GPM (L/s) 2 (0.13) 3 (0.19) 4 (0.25) 5 (0.32) 6 (0.38) 7 (0.44) 8 (0.50) 9 (0.57) 10 (0.63) 11 (0.69) 12 (0.76) 14 (0.88) 16 (1.01) 18 (1.14) 20 (1.26) 22 (1.39) 1/2 (12 mm) 13.6 [1.3] 28.8 [2.8] 49.1 [4.8] 74.3 [7.3] 104.0 [10.2] 138.4 [13.6] 3/4" (20 mm) 1.2 [0.1] 2.3 [0.2] 4.2 [0.4] 6.2 [0.6] 8.8 [0.9] 11.5 [1.1] 14.8 [1.5] 18.5 [1.8] 22.4 [2.2] 26.8 [2.6] 31.4 [3.1] 1" (25 mm) 0.5 [0.05] 0.9 [0.09] 1.4 [0.1] 2.1 [0.2] 3.0 [0.3] 3.9 [0.4] 5.1 [0.5] 6.2 [0.6] 7.6 [0.8] 9.0 [0.9] 10.6 [1.0] 14.1 [1.4] 18.0 [1.8] 22.4 [2.2] 27.2 [2.7] 32.5 [3.2]
3

38.1 [3.7] 24 (1.51) Highlighted numbers indicate maximum recommended flowrate.

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Table 5: Copper Pipe Pressure Losses (Type L) Flow Rate, GPM (L/s) 1 (0.08) 2 (0.13) 3 (0.19) 4 (0.25) 5 (0.32) 6 (0.38) 7 (0.44) 8 (0.50) 9 (0.57) 10 (0.63) 11 (0.69) 12 (0.76) 14 (0.88) 16 (1.01) 18 (1.14) 20 (1.26) 22 (1.39) 24 (1.51) 26 (1.64) 28 (1.77) 30 (1.89) 32 (2.02) 34 (2.15) 36 (2.27) Pressure Drop, ft water/100 ft (kPa/m) " (12 mm) 2.7 [0.26] 10.0 [0.98] 21.0 [2.10] 3/4" (20 mm) 0.4 [0.04] 1.5 [0.15] 3.1 [0.30] 5.4 [0.53] 8.0 [0.78] 11.0 [1.1] 15.0 [1.5] 19.0 [1.9] 1" (25 mm) 0.4 [0.04] 0.8 [0.08] 1.3 [0.13] 2.0 [0.20] 2.8 [0.27] 3.6 [0.35] 4.6 [0.45] 5.9 [0.58] 7.0 [0.69] 8.5 [0.83] 10.0 [0.98] 13.0 [1.3] 17.0 [1.7] 21.0 [2.1] 1-1/4" (32 mm) 0.3 [0.03] 0.5 [0.05] 0.8 [0.07] 1.0 [0.10] 1.4 [0.14] 1.7 [0.17] 2.1 [0.21] 2.6 [0.26] 3.1 [0.30] 3.6 [0.35] 5.0 [0.49] 6.1 [0.60] 7.7 [0.76] 9.5 [0.93] 11.0 [1.1] 13.0 [1.3] 15.5 [1.5] 17.5 [1.7] 20.0 [2.0] 1-1/2" (38 mm) 0.2 [0.02] 0.3 [0.03] 0.5 [0.04] 0.6 [0.05] 0.8 [0.07] 0.9 [0.09] 1.1 [0.11] 1.3 [0.13] 1.5 [0.15] 2.0 [0.20] 2.6 [0.26] 3.2 [0.31] 4.0 [0.39] 4.6 [0.45] 5.5 [0.54] 6.5 [0.64] 7.3 [0.72] 8.2 [0.80] 9.4 [0.92] 10.5 [1.03] 11.5 [1.13] 2" (51 mm) 0.2 [0.02] 0.3 [0.03] 0.3 [0.03] 0.4 [0.04] 0.5 [0.05] 0.7 [0.06] 0.8 [0.08] 1.0 [0.10] 1.2 [0.12] 1.4 [0.14] 1.6 [0.16] 1.8 [0.18] 2.0 [0.20] 2.3 [0.23] 2.6 [0.26] 2.9 [0.28]

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Table 6: PEX Pipe Pressure Losses Flow rate, GPM (L/s) 1/2 (12 mm) 3/4 (20 mm) 1 (0.08) 3.7 [0.36] 0.7 [0.07] 2 (0.13) 3 (0.19) 4 (0.25) 5 (0.32) 6 (0.38) 7 (0.44) 8 (0.50) 9 (0.57) 10 (0.63) 11 (0.69) 12 (0.76) 14 (0.88) 16 (1.01) 18 (1.14) 20 (1.26) 22 (1.39) 24 (1.51) 26 (1.64) 28 (1.77) 30 (1.89) 32 (2.02) 34 (2.15) 12.7 [1.3] 26.1 [2.6] 43.8 [4.3] 65.3 [6.4] 90.7 [8.9] 2.5 [0.25] 5.1 [0.50] 8.5 [0.83] 12.9 [1.3] 17.8 [1.8] 23.5 [2.3] 29.8 [2.9] 36.9 [3.6] 44.5 [4.4] 52.8 [5.2] 61.8 [6.1] -

Pressure Drop, ft water/100 ft (kPa/m) 1 (25 mm) 1-1/4 (32 mm) 0.2 [0.02] 0.09 [0.01] 0.7 [0.07] 1.6 [0.16] 2.5 [0.25] 3.9 [0.38] 5.3 [0.52] 7.2 [0.71] 9.0 [0.88] 11.1 [1.1] 13.4 [1.3] 15.9 [1.6] 18.7 [1.8] 24.5 [2.4] 31.1 [3.1] 38.5 [3.8] 46.6 [4.6] 0.2 [0.02] 0.7 [0.07] 0.9 [0.1] 1.4 [0.14] 2.1 [0.21] 2.8 [0.27] 3.5 [0.34] 4.2 [0.41] 5.1 [0.50] 6.0 [0.59] 7.2 [0.71] 9.5 [0.93] 12.0 [1.2] 14.8 [1.5] 17.8 [1.8] 21.2 [2.1] 24.7 [2.4] 28.6 [2.8] 32.8 [3.2] 36.9 [3.6] -

1-1/2 (38 mm) 0.05 [0.005] 0.14 [0.01] 0.2 [0.02] 0.5 [0.05] 0.7 [0.07] 0.9 [0.10] 1.2 [0.12] 1.6 [0.16] 1.8 [0.18] 2.3 [0.23] 2.8 [0.27] 3.2 [0.31] 4.2 [0.41] 5.3 [0.52] 6.7 [0.66] 8.1 [0.79] 9.5 [0.93] 11.1 [1.1] 12.9 [1.3] 14.8 [1.5] 16.6 [1.6] 18.7 [1.8] 20.8 [2.0] 23.1 [2.3]

2 (51 mm) 0.01 [0.001] 0.05 [0.005] 0.07 [0.007] 0.1 [0.01] 0.2 [0.02] 0.2 [0.02] 0.2 [0.02] 0.5 [0.05] 0.5 [0.05] 0.7 [0.07] 0.7 [0.07] 0.9 [0.10] 1.2 [0.12] 1.4 [0.14] 1.8 [0.18] 2.3 [0.23] 2.5 [0.25] 3.0 [0.29] 3.5 [0.34] 3.9 [0.38] 4.6 [0.45] 5.1 [0.50] 5.8 [0.57] 6.2 [0.61]

36 (2.27) Highlighted numbers indicate 8 f/s maximum velocity required by some plumbing codes.

Bulletin 40-60 (October 2004) Page 13

Table 7: PVC Pipe (Schedule 80) Pressure Losses Flow rate, GPM Pressure Drop, ft water/100 ft (kPa/m) (L/s) 1/2 (12 mm) 3/4 (20 mm) 1 (25 mm) 1-1/4 (32 mm) 1-1/2 (38 mm) 1 (0.08) 2.5 [0.2] 0.6 [0.06] 2 (0.13) 3 (0.19) 4 (0.25) 5 (0.32) 6 (0.38) 7 (0.44) 8 (0.50) 9 (0.57) 10 (0.63) 11 (0.69) 12 (0.76) 14(0.88) 16 (1.01) 18 (1.14) 20 (1.26) 22 (1.39) 24 (1.51) 26 (1.64) 28 (1.77) 30 (1.89) 32 (2.02) 34 (2.15) 8.5 [0.8] 17.0 [1.7] 27.0 [2.6] 1.9 [0.2] 4.0 [0.4] 6.5 [0.6] 9.5 [0.9] 13.0 [1.3] 17.0 [1.7] 22.0 [2.2] 26.0 [2.6] 30.0 [2.9] 0.7 [0.07] 1.2 [0.1] 1.9 [0.2] 2.9 [0.3] 4.0 [0.4] 5.0 [0.5] 6.5 [0.6] 8.0 [0.8] 9.5 [0.9] 11.5 [1.1] 13.0 [1.3] 17.0 [1.7] 21.0 [2.1] 25.0 [2.5] 31.0 [0.3] 0.5 [0.05] 0.7 [0.07] 1.0 [0.1] 1.3 [0.1] 1.7 [0.2] 2.0 [0.2] 2.4 [0.2] 2.7 [0.3] 3.2 [0.3] 4.5 [0.4] 5.4 [0.5] 7.0 [0.7] 8.0 [0.8] 9.5 [0.9] 11.5 [1.1] 13.5 [1.3] 15.0 [1.5] 16.5 [1.6] 18.0 [1.8] 20.0 [2.0] 23.0 [2.3] 0.6 [0.06] 0.8 [0.08] 0.9 [0.09] 1.2 [0.12] 1.4 [0.14] 1.5 [0.15] 2.0 [0.20] 2.5 [0.25] 3.4 [0.33] 3.9 [0.4] 4.5 [0.4] 5.0 [0.5] 6.0 [0.6] 7.0 [0.7] 8.0 [0.8] 8.5 [0.8] 9.5 [0.9] 11.0 [1.1]

2 (51 mm) 0.4 [0.04] 0.6 [0.06] 0.8 [0.08] 1.0 [0.10] 1.2 [0.12] 1.3 [0.13] 1.4 [0.14] 1.8 [0.18] 2.0 [0.20] 2.4 [0.24] 2.5 [0.25] 2.7 [0.26] 3.0 [0.29]

36 (2.27) Highlighted numbers indicate velocity over 4 f/s.

Bulletin 40-60 (October 2004) Page 14

PUMP PERFORMANCE CURVE The Unichiller pumps are stainless steel. They are 0.75-horsepower for the 3-ton unit and 1.35horsepower for the 5-ton. Figure 3 shows the pump performance curves. A performance curve displays the pump power required for a liquid with a specific gravity of 1.0 (water) over a particular range of impeller diameters and flows. Head vs. Capacity curve represents the difference in total head between the suction side and the discharge side of the pump. The discharge head decreases as the flow increases. A system curve displays the system head required to produce a given flow rate for a liquid and its characteristics in a piping system design. To produce a given flow, the system head must overcome pipe friction, actual fitting and valve losses, resistance to flow due to fluid viscosity, and possible system effect losses. Piping system pressure drop calculations are explained in the corresponding section below. The calculated total pressure drop can be used to plot the system curve. The pump and the system curves can be plotted on the same graph. The intersection of the two curves is the operating point.

Figure 3: Pump Performance Curves (3-ton and 5-ton, 60 Hz) with an Example System Curve

Bulletin 40-60 (October 2004) Page 15

EXAMPLES OF PRESSURE DROP CALCULATIONS AND PIPE SIZING When calculating pipe sizes, the piping loop with the most restriction (most pressure drop) must be considered. If the pump can supply liquid solution to the most restrictive loop, then it will supply to the other loops. The most restrictive loop in a system is usually the furthest and biggest air handler. Start pipe sizing by selecting a pipe size that will be approximately enough. Then perform the detailed calculations to ensure the pipe selected is right. Table 8 lists the estimated pipe sizes for different types of pipes. It can be used as a starting point for pipe sizing. However, the results may change if the chiller is closer or further than assumed, or if there is more glycol in the system, etc.
Table 8: Estimated Pipe Sizes Based on Flowrate Total Flowrate, Composite Pipe Copper Pipe, PEX, in PVC, in gpm (Kitec), in in 1 1-3 3-4 1 5 1 1 5-6 1 1 1 1 6-8 1 1 1-1/4 1 8-9 1 1 1-1/4 1-1/4 9-11 1-1/4 1-1/4 1-1/4 11-16 1-1/4 1-1/2 1-1/4 16-18 1-1/2 1-1/2 1-1/2 18-24 1-1/2 2 1-1/2 24-26 1-1/2 2 2 26-36 2 2 2 These are typical pipe sizes for a system with a 5-ton Unichiller with multiple air handlers. The furthest and largest air handler is a MC3660W 150 ft away from the Unichiller. 10% propylene glycol is in the system.

Example 1: Quick Estimate (Conservative in most cases) Given: The distance between the farthest air handler and the Unichiller is 170 feet (supply and return total). All air handlers are MC2430W units.
12 gpm 4 gpm 4 gpm 4 gpm

5-ton Unichiller

AHU1

AHU2

AHU3

NOTE: Valves are not shown.

Find: The required copper pipe size. Purpose: To find the maximum pressure drop without exceeding the pumps capability. Solution: Try 1-inch copper pipe first. Since all the air handlers are installed in parallel and have the same flow rate, you only need to calculate the pressure drop for the air handler furthest from the chiller, which has the most restriction. For the quick analysis, consider 12 gpm in all pipes. This is the worst case situation. 170 feet of pipe x 150% = 255 equivalent feet of pipe 10.0 feet of water / 100 feet of pipe @12 GPM (Table 5)

Bulletin 40-60 (October 2004) Page 16

2.55 x 10.0

= 25.5 ft of water
25.5 45.0 3.5 74.0

Piping and fittings pressure drop, ft of water Unichiller pressure drop, ft of water (Table 1) Furthest AHU pressure drop, ft of water (Table 2) TOTAL PRESSURE DROP, ft of water

Conclusion: The calculated pressure drop (74 ft of water) is less than the pumps 90 ft of water rating so 1-inch copper pipe size is correct. It is left to the installer to adjust the balancing valves to provide proper flow rate to each air handler. The effect of propylene glycol is ignored for the simplicity of the example. Example 2 Given:
100 ft 20ft 12 gpm 4 gpm 8 gpm

A
8 gpm

35ft

5-ton Unichiller

2-ton AHU1
MC2430W

3-ton AHU2
MC3660W

20ft

100 ft

35ft

20% propylene glycol-water solution is in the system. Find: The required copper pipe size. Purpose: To find the maximum pressure drop without exceeding the pumps capability. Solution: Try 1-inch copper pipe first. First, look up the pressure drop through the piping based on pipe size and water flow rate using Tables 4 through 7. Then multiply the pressure drop by the equivalent length and divide by 100.
Trial Pipe Diameter and Type 1 copper 1 copper 1 copper 1 copper 1 copper 1 copper Flowrate, gpm 12 4 4 12 8 8 Length, ft 100 20 20 100 35 35 Equivalent Length, ft (150% of length) 150 30 30 150 52.5 52.5 ft of water /100ft pipe (Table 5) 10.0 1.3 1.3 10.0 4.6 4.6 Pressure Drop, ft of water 15.0 0.4 0.4 15.0 2.4 2.4

UCH to A A to AHU1 AHU1 to B B to UCH A to AHU2 AHU2 to B

Add pressure drops from the Unichiller, air handler and piping to get the total pressure drop.
With 20% propylene glycol (Pressure drop multipliers from Tables 10, 11 and 12)
Loop Unichiller Pressure Drop (Table 1), ft of water AHU Pressure Drop (Table 2), ft of water Piping Pressure Drop (Table 5), ft of water TOTAL PRESSURE DROP

Bulletin 40-60 (October 2004) Page 17

UCH to AHU1 UCH to AHU2

45 x 1.03 45 x 1.03

3.5 x 0.88 8.1 x 0.88

30.8 x 1.07 34.8 x 1.07

82.4 90.7

2nd Trial: UCH to AHU2 loop exceeds the pumps allowable 90 ft of water limit so upsize the main piping (UCH to A and B to UCH) to 1-1/4-inch pipe. Try -inch pipe for very low pressure drop segments to find the minimum allowable pipe size. The pressure drops for A to AHU1 and AHU1 to B segments are very low so reduce to -inch pipe.
Trial Pipe Diameter and Type 1-1/4 copper copper copper 1-1/4 copper 1 copper 1 copper Flowrate, gpm 12 4 4 12 8 8 Length, ft 100 20 20 100 35 35 Equivalent Length, ft (150% of length) 150 30 30 150 52.5 52.5 ft of water /100ft pipe (Table 5) 3.6 5.4 5.4 3.6 4.6 4.6 Pressure Drop, ft of water 5.4 1.6 1.6 5.4 2.4 2.4

UCH to A A to AHU1 AHU1 to B B to UCH A to AHU2 AHU2 to B

With 20% propylene glycol (Pressure drop multipliers from Tables 10, 11 and 12)
Loop UCH to AHU1 UCH to AHU2 Unichiller Pressure Drop (Table 1), ft of water 45 x 1.03 45 x 1.03 AHU Pressure Drop (Table 2), ft of water 3.5 x 0.88 8.1 x 0.88 Piping Pressure Drop (Table 5), ft of water 14 x 1.07 15.6 x 1.07 TOTAL PRESSURE DROP 64.4 70.2

Conclusion: The maximum calculated pressure drop (70.2 ft of water) is less than the pumps 90 ft of water rating so copper pipe sizes selected in the 2nd trial are correct. It is left to the installer to adjust the balancing valves to provide proper flow rate to each air handler. Example 3 Given:
50ft

20ft 9.5 gpm

30ft 5 gpm

40ft

12 gpm

2.5 gpm

2.5 gpm 4.5 gpm 20ft 20ft

2.5 gpm

20ft

5-ton Unichiller

1.5-ton AHU1
M1218

2.5-ton AHU2
MC3660W

1.5-ton AHU3
M1218

1.5-ton AHU4
M1218

20ft

20ft

20ft

9.5 gpm 50ft NOTE: Valves are not shown.

5 gpm

20ft

30ft

40ft

30% propylene glycol-water solution is in the system. Find: The required copper pipe size for each branch. Purpose: To find the maximum pressure drop without exceeding the pumps capability.

Bulletin 40-60 (October 2004) Page 18

Solution: The above schematic is an example of a piping layout made up of multiple individual solution circuits. With this type of layout, if you can supply the required solution to the greatest pressure drop circuit in the system, the shorter circuits will have sufficient liquid solution, as their pressure drops are less. Select 1-inch copper pipe for the main piping and -inch copper pipe for the branch piping.
Trial Pipe Diameter Flowrate, Length, ft and Type gpm UCH to A 1 copper 12.0 50 A to AHU1 copper 2.5 20 AHU1 to D copper 2.5 20 D to UCH 1 copper 12.0 50 A to B 1 copper 9.5 20 B to AHU2 copper 4.5 20 AHU2 to E copper 4.5 20 E to D 1 copper 9.5 20 B to C 1 copper 5.0 30 C to AHU3 copper 2.5 20 AHU3 to F copper 2.5 20 F to E 1 copper 5.0 30 C to AHU4 copper 2.5 40 AHU4 to F copper 2.5 40 * Estimate the pressure drops for some of the flow rates. Unichiller Pressure Drop (Table 1), ft of water 45 x 1.07 45 x 1.07 45 x 1.07 45 x 1.07 Equivalent Length, ft (150% of length) 75 30 30 75 30 30 30 30 45 30 30 45 60 60 ft of water /100ft pipe (Table 5*) 10.0 2.4 2.4 10.0 6.5 6.6 6.6 6.5 2.0 2.4 2.4 2.0 2.4 2.4 Pressure Drop, ft of water 7.5 0.7 0.7 7.5 2.0 2.0 2.0 2.0 0.9 0.7 0.7 0.9 1.4 1.4

With 30% propylene glycol (Pressure drop multipliers from Tables 10, 11 and 12)
Loop UCH to AHU1 UCH to AHU2 UCH to AHU3 UCH to AHU4 AHU Pressure Drop (Table 2), ft of water 1.8 x 1.1 4.5 x 1.1 1.8 x 1.1 1.8 x 1.1 Piping Pressure Drop (Table 5), ft of water 16.4 x 1.25 23.0 x 1.25 22.2 x 1.25 23.6 x 1.25 TOTAL PRESSURE DROP 70.6 81.6 77.9 79.6

Conclusion: After comparing pressure drops from all 4 air handlers, air handler 2 has the greatest pressure drop of 81.6 ft of water, which is less than the 90 ft of water rating of the pump. Therefore, the pump will deliver the required solution to the air handlers using the selected pipe sizes. Example 4: 2 Unichillers, 4 Air Handlers Given:
10ft

80ft 20 gpm 8 gpm

20ft 15 gpm 5 gpm

10ft 11 gpm 4 gpm

20ft

12 gpm 10ft 15ft

6 gpm

5 gpm

10ft

10ft

5-ton Unichiller

3-ton Unichiller

2-ton AHU1
MC2430W

1-ton AHU2
M1218

3-ton AHU3
MC3660W

2-ton AHU4
MC2430W

10ft

15ft

10ft

10ft

10ft

80ft

20ft

10ft

20ft

NOTE: Valves are not shown.

Bulletin 40-60 (October 2004) Page 19

20% propylene glycol-water solution is in the system. Find: The required copper pipe size for each branch. Purpose: To find the maximum pressure drop without exceeding the pumps capability. Solution: The above schematic is an example of a piping layout made up of multiple individual solution circuits. With this type of layout, if you can supply the required solution to the greatest pressure drop circuit in the system, the shorter circuits will have sufficient liquid solution, as their pressure drops are less. Start by selecting -inch pipe for low flow segments (6 gpm or less), 1-1/4inch for high glow segments (20 gpm) and 1-inch for the remaining segments.
5-ton UCH to A 3-ton UCH to A A to B B to AHU1 B to C C to AHU2 C to D D to AHU3 D to AHU4 AHU4 to H AHU3 to H H to G AHU2 to G G to F AHU1 to F F to E E to 3-ton UCH E to 5-ton UCH Trial Pipe Diameter and Type 1 copper 1 copper 1-1/4 copper copper 1 copper copper 1 copper copper copper copper copper 1 copper copper 1 copper copper 1-1/4 copper 1 copper 1 copper Flowrate, gpm 12 8 20 5 15 4 11 6 5 5 6 11 4 15 5 20 8 12 Length, ft 10 10 80 15 20 10 10 10 20 20 10 10 10 20 15 80 10 10 Equivalent Length, ft (150% of length) 15.0 15.0 120.0 22.5 30.0 15.0 15.0 15.0 30.0 30.0 15.0 15.0 15.0 30.0 22.5 120.0 15.0 15.0 ft of water /100ft pipe (Table 5) 10.0 4.6 9.5 8.0 15.0 5.4 8.5 11.0 8.0 8.0 11.0 8.5 5.4 15.0 8.0 9.5 4.6 10.0 Pressure Drop, ft of water 1.5 0.7 11.4 1.8 4.5 0.8 1.3 1.7 2.4 2.4 1.7 1.3 0.8 4.5 1.8 11.4 0.7 1.5

With 20% propylene glycol (Pressure drop multipliers from Tables 10, 11 and 12)
Loop 5-ton UCH to AHU1 5-ton UCH to AHU2 5-ton UCH to AHU3 5-ton UCH to AHU4 3-ton UCH to AHU1 3-ton UCH to AHU2 3-ton UCH to AHU3 3-ton UCH to AHU4 Unichiller Pressure Drop (Table 1), ft of water 45 x 1.03 45 x 1.03 45 x 1.03 45 x 1.03 10 x 1.03 10 x 1.03 10 x 1.03 10 x 1.03 AHU Pressure Drop (Table 2), ft of water 5.3 x 0.88 3.4 x 0.88 4.8 x 0.88 5.3 x 0.88 5.3 x 0.88 3.4 x 0.88 4.8 x 0.88 5.3 x 0.88 Piping Pressure Drop (Table 5), ft of water 29.4 x 1.07 36.4 x 1.07 40.8 x 1.07 42.2 x 1.07 27.8 x 1.07 34.8 x 1.07 39.2 x 1.07 40.6 x 1.07 TOTAL PRESSURE DROP 82.5 88.3 94.2 96.2 44.7 50.5 56.5 58.4

2nd Trial: The total pressure drop exceeds the available by the pump so increase the size of the pipe and recalculate. Increase high flow segments to 1-1/2-inch since they have the most pressure drop.
5-ton UCH to A 3-ton UCH to A A to B B to AHU1 B to C C to AHU2 C to D D to AHU3 D to AHU4 AHU4 to H AHU3 to H H to G Trial Pipe Diameter and Type 1 copper 1 copper 1-1/2 copper copper 1 copper copper 1 copper copper copper copper copper 1 copper Flowrate, gpm 12 8 20 5 15 4 11 6 5 5 6 11 Length, ft 10 10 80 15 20 10 10 10 20 20 10 10 Equivalent Length, ft (150% of length) 15.0 15.0 120.0 22.5 30.0 15.0 15.0 15.0 30.0 30.0 15.0 15.0 ft of water /100ft pipe (Table 5) 10.0 4.6 4.0 8.0 15.0 5.4 8.5 11.0 8.0 8.0 11.0 8.5 Pressure Drop, ft of water 1.5 0.7 4.8 1.8 4.5 0.8 1.3 1.7 2.4 2.4 1.7 1.3

Bulletin 40-60 (October 2004) Page 20

AHU2 to G G to F AHU1 to F F to E E to 3-ton UCH E to 5-ton UCH

copper 1 copper copper 1-1/2 copper 1 copper 1 copper

4 15 5 20 8 12

10 20 15 80 10 10

15.0 30.0 22.5 120.0 15.0 15.0

5.4 15.0 8.0 4.0 4.6 10.0

0.8 4.5 1.8 4.8 0.7 1.5

With 20% propylene glycol (Pressure drop multipliers from Tables 10, 11 and 12)
Loop 5-ton UCH to AHU1 5-ton UCH to AHU2 5-ton UCH to AHU3 5-ton UCH to AHU4 3-ton UCH to AHU1 3-ton UCH to AHU2 3-ton UCH to AHU3 3-ton UCH to AHU4 Unichiller Pressure Drop (Table 1), ft of water 45 x 1.03 45 x 1.03 45 x 1.03 45 x 1.03 10 x 1.03 10 x 1.03 10 x 1.03 10 x 1.03 AHU Pressure Drop (Table 2), ft of water 5.3 x 0.88 3.4 x 0.88 4.8 x 0.88 5.3 x 0.88 5.3 x 0.88 3.4 x 0.88 4.8 x 0.88 5.3 x 0.88 Piping Pressure Drop (Table 5), ft of water 16.2 x 1.07 23.2 x 1.07 27.6 x 1.07 29.0 x 1.07 14.6 x 1.07 21.6 x 1.07 26.0 x 1.07 27.4 x 1.07 TOTAL PRESSURE DROP 68.3 74.2 80.1 82.0 30.6 36.4 42.3 44.3

Conclusion: After comparing pressure drops from all 4 air handlers, air handler 4 has the greatest pressure drop of 82.0 ft of water which is less than the 90 ft of water rating of the pump (5-ton Unichiller). Therefore, the pump will deliver the required solution to the air handlers using the selected pipe sizes. DETERMINE PROPYLENE GLYCOL PERCENTAGE The fluid in the system must contain at least 10% propylene glycol. The following table lists the percentage of propylene glycol that should be in the liquid solution based on minimum ambient temperatures.
Table 9: Percent of Propylene Glycol to Water Content

Propylene Glycol % Minimum F Ambient C Temperature

10% 26 -3.3

20% 18 -7.8

30% 8 -12.8

40% -7 -21.7

50% -29 -33.9

How to put propylene glycol in the system Propylene glycol should be mixed with water before introducing the solution in the system to ensure proper mixing. EFFECT OF PROPYLENE GLYCOL ON AIR HANDLERS AND UNICHILLER The glycol will affect the capacity and the pressure drop of the system. Tables 10, 11 and 12 show the effect of propylene glycol on Unichiller, Unico air handlers and copper piping, respectively.
Table 10: Effect of Propylene Glycol on Unichiller

Percent Propylene Glycol by Weight Capacity Multiplier Pressure Drop Multiplier Percent Propylene Glycol by Weight

10% 0.99 1.01 10%

20% 0.98 1.03 20%

30% 0.98 1.07 30%

40% 0.97 1.11 40%

50% 0.96 1.16 50%

Table 11: Effect of Propylene Glycol on Unico Air Handlers

Bulletin 40-60 (October 2004) Page 21

Capacity Multiplier Pressure Drop Multiplier

0.94 0.94

0.85 0.88

0.83 1.10

0.81 1.42

0.79 2.04

* Data for MC2430W with 600 CFM at 80F dry bulb, 67F wet bulb, 6 GPM, 40F entering water temperature.

Table 12: Effect of Propylene Glycol on Copper Piping

Percent Propylene Glycol by Weight Pressure Drop Multiplier

10% 1.00

20% 1.07

30% 1.25

40% 1.40

50% 1.65 Equation (1) Equation (2)

Pressure Drop = (Water Pressure Drop) x (Pressure Drop Multiplier) Capacity = (Capacity Using Water) x (Capacity Multiplier)

Please refer to specific PEX piping manufacturers catalog for the effect of propylene glycol. To size the Unichiller, air handlers and piping correctly, use Tables 10, 11 and 12 and the above equations. Below is an example demonstrating how to size the Unichiller and air handlers correctly. Example Given: The house requires 30,000 Btuh of cooling. Only 10% propylene glycol is necessary (The minimum outdoor temperature is 30F). Find: The correct air handler and Unichiller sizes. Solution: The best way to size both the air handler and the Unichiller properly is to start with sizing the air handler. Using equation (2) above: Capacity = 30,000 Btu/h x 0.94 = 28,200 Btuh 28,200 Btuh is the capacity you can get if the air handler is sized for 30,000 Btuh. To actually get the 30,000 Btuh of cooling, divide the desired capacity by the capacity multiplier. Required Capacity (from air handler capacity tables) = 30,000 Btuh / 0.94 = 31,915 Btuh So size the air handler for 31,915 Btuh. The next step is to size the Unichiller. The capacity you can get out of the Unichiller if you sized for 31,915 Btuh is calculated by equation (1) above: Capacity = 31,915 x 0.99 = 31,596 Btuh To calculate the required Unichiller capacity, divide the air handler capacity required by the Unichiller capacity multiplier. Required Capacity (Unichiller) = 31,915 Btuh / 0.99 = 32,237 Btuh So size the Unichiller for 32,237 Btuh. STORAGE TANK Installing a storage tank is necessary if the total system volume is less than 25 gallons. You need 25 gallons in the system for the first chiller, then 10 gallons each for the other chillers. However, you do not need to install a storage tank, although it is recommended, if there is only one load on the system. A single load can be either one air handler or more than one air handler provided they operate simultaneously from a single thermostat.

Bulletin 40-60 (October 2004) Page 22

The following tables show the liquid solution capacities of composite piping (Kitec), copper piping, PEX piping, PVC piping, Unichiller, and Unico Air Handlers:
Table 13: Liquid solution capacities of different types of piping

Type Composite Pipe (Kitec)

Copper Pipe

PEX Pipe

PVC Pipe

Pipe Size, in (mm) (12) (20) 1 (25) (12) (20) 1 (25) 1-1/4 (32) 1-1/2 (38) 2 (51) (12) (20) 1 (25) 1-1/4 (32) 1-1/2 (38) 2 (51) (12) (20) 1 (25) 1-1/4 (32) 1-1/2 (38) 2 (51)

Volume, Gal/ft (L/m) 0.009 (0.11) 0.025 (0.31) 0.030 (0.37) 0.012 (0.15) 0.025 (0.32) 0.043 (0.54) 0.065 (0.82) 0.092 (1.16) 0.161 (2.03) 0.009 (0.11) 0.018 (0.22) 0.030 (0.37) 0.045 (0.57) 0.067 (0.85) 0.105 (1.33) 0.015 (0.19) 0.027 (0.34) 0.044 (0.56) 0.076 (0.96) 0.103 (1.30) 0.171 (2.16)
Table 15: Unico air handler liquid solution capacities

Table 14: Unichiller liquid solution capacities

Unichiller Size UCHR-036-1-1 UCHR-036-1-6 UCHR-060-1-1 UCHR-060-1-7

Volume, Gal (L) 1 (3.79)

AHU Size M1218+CW MC2430W MC3660W

Volume, Gal (L) 0.7 (2.6) 1.0 (3.8) 1.6 (6.1)

Water Volume Calculation Example Chiller: Two UCH-060-1 Piping: 300' of 1" composite pipe AHUs: Four MC2430W Expansion Tank: Total Volume 2 9 4 1 16 gallons

The volume requirement is 25+10=35 gallons; therefore, a storage tank of at least 35-16=19 gallons is needed.

PIPING SCHEMATICS (PARALLEL PIPING)

Return water

Mixed water

Domestic Water Source Automatic Fill Area (optional)

Drain Unichiller (pump included). Isolation valve. Vent/Purge valve. Install vent at the highest point. Unico air handler. Two-way valve (to drain). Install drain at the lowest point. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be. Backflow preventer. Automatic fill valve. Pressure gage. Pressure regulator. Strainer.
IL00353.CNV

The following are the parallel piping schematics for the most common installations.

Bulletin 40-60 (October 2004) Page 23

Figure 4: 1 Chiller, 1 Unico Air Handler

A A B AB B AB

Mixed water Return water Return water

Domestic Water Source Automatic Fill Area (optional)

Drain

Unichiller (pump included). Pressure gage.

Isolation valve.

Backflow preventer. Automatic fill valve. Pressure regulator. Strainer. Balancing valve. Three-way valve. Storage tank.
IL00354.CNV

Vent/Purge valve. Install vent at the highest point. Unico air handler.

Two-way valve (to drain). Install drain at the lowest point. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be.

Bulletin 40-60 (October 2004) Page 24

Figure 5: 1 Chiller, Multiple Unico Air Handlers

A B AB B

AB

Return water Mixed water

Return water
P

Domestic Water Source Automatic Fill Area (optional) Drain

Unichiller (pump included). Isolation valve. Vent/Purge valve. Install vent at the highest point. Unico air handler.

Backflow preventer. Automatic fill valve. Pressure gage. Pressure regulator. Strainer. Balancing valve. Three-way valve. Storage tank. Check valve.
IL00355.CNV

Two-way valve (to drain). Install drain at the lowest point. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be.

Bulletin 40-60 (October 2004) Page 25

Figure 6: Multiple Chillers, Multiple Unico Air Handlers

A A AB AB B B

Return water Mixed water

Return water
P

Domestic Water Source Automatic Fill Area (optional) Drain

Unichiller (pump included). Isolation valve. Vent/Purge valve. Install vent at the highest point. Unico air handler.

Pressure gage. Pressure regulator. Strainer. Balancing valve. Three-way valve. Storage tank. Check valve. Boiler. Pump.
IL00356a.CNV

Refer to boiler manufacturers installation manual for more details on boiler piping.

Two-way valve (to drain). Install drain at the lowest point. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be. Backflow preventer. Automatic fill valve.

Bulletin 40-60 (October 2004) Page 26

Figure 7: 1 Chiller, 1 Boiler, Multiple Unico Air Handlers

PIPING SCHEMATICS (PRIMARY-SECONDARY PIPING)

No more than 12" apart

Drain Water Fill Area

Unichiller (pump included). Isolation valve. Circulator/Zone pump. Vent/Purge valve. Install vent at the highest point (one per loop). Unico air handler.

The following are the primary-secondary piping schematics for the most common installations.

Storage tank. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be. Strainer. Two-way valve (to drain). Install drain at the lowest point.

IL00370.CNV

Bulletin 40-60 (October 2004) Page 27

Figure 8: 1 Chiller, Multiple Unico Air Handlers Primary/Secondary Piping

No more than 12" apart

Drain Water Fill Area

Unichiller (pump included). Isolation valve. Circulator/Zone pump. Vent/Purge valve. Install vent at the highest point (one per loop). Unico air handler. Storage tank.

Expansion tank. Reference pressure point. The higher the tank, the smaller it can be. Strainer. Two-way valve (to drain). Install drain at the lowest point. Check valve.

IL00371.CNV

Bulletin 40-60 (October 2004) Page 28

Figure 9: Multiple Chiller, Multiple Unico Air Handlers Primary/Secondary Piping

No more than 12" apart

Drain Water Fill Area

Unichiller (pump included). Isolation valve.

Strainer. Two-way valve (to drain). Install drain at the lowest point. Check valve. Boiler. Boiler pump.
IL00372.CNV

Refer to boiler manufacturers installation manual for more details on boiler piping.

Circulator/Zone pump. Vent/Purge valve. Install vent at the highest point (one per loop). Unico air handler. Storage tank. Expansion tank. Reference pressure point. The higher the tank, the smaller it can be.

Bulletin 40-60 (October 2004) Page 29

Figure 10: 1 Chiller, 1 Boiler, Multiple Unico Air Handlers Primary/Secondary Piping

Bulletin 40-60 (October 2004) Page 30

WIRING

! !

Before operating, be sure the unit is properly grounded to prevent injury or death from electrical shock! Disconnect electrical supply before wiring unit to prevent injury or death from electrical shock!

All electrical wiring should be in accordance with the latest edition of the National Electric Code and all local codes and regulations. The unit is safety certified to UL 1995, CAN/CSA STD C22.2 NO. 236 and listed with ETL. Ladder Wiring Schematic

Figure 11: Reverse Cycle Unichiller Ladder Diagram

Connect power to the contactor as shown (black and white wires). Connect the green wire to the ground.

Bulletin 40-60 (October 2004) Page 31

Pictorial Wiring Diagram

Figure 12: Reverse Cycle Unichiller Pictorial Wiring Diagram

Bulletin 40-60 (October 2004) Page 32

STARTUP Sequence of Operation OFF MODE (UCHR only): There is no power going to the unit when the unit is in this mode.

COOL HEAT OFF

COOLING MODE: When power is applied from the circuit breaker, the control transformer is energized. The pump bypass timer (10 second timer) temporarily bypasses the flow switch. The pump starts to move the liquid solution if the system is properly filled and air purged. The digital temperature controller is also activated when the pump is energized. If after 10 seconds the flow switch shuts off for any reason, the system will stop and must be manually re-energized. If the temperature controller calls for cooling, then the compressor and the fans are energized.

HEATING MODE (UCHR only): When the power is applied from the circuit breaker, the control transformer is energized. The reversing valve is also energized, reversing the flow of the refrigerant to make hot water. The pump bypass timer (10 second timer) temporarily bypasses the flow switch. The pump starts to move the liquid solution, if the system is properly filled and air purged. The digital temperature controller is also activated when the pump is energized. If after 10 seconds the flow switch shuts off for any reason, the system will stop and must be manually re-energized. If the temperature controller calls for heating, then the compressor and the fans are energized. In the heating mode, there is a defrost mode, which is based on the surrounding air temperature. In the defrost mode, the direction of the refrigerant flow is reversed to direct hot refrigerant through the condensing coil to prevent the excessive frosting of the coil. The defrost mode is terminated when the temperature of the condensing coil exceeds the field-selectable termination temperature (50, 60, 70 or 80F). The default termination temperature is 70F, therefore, the defrost mode will terminate when the coil temperature reaches 70F. In a colder climate, the setting can be raised to ensure the defrosting of the coil. Similarly, in a warmer climate, the setting can be lowered so that the unit is not in the defrost mode longer than it needs to. There is a five-minute time delay after each time the compressor is shut down. The pump will run continuously in the cooling and heating modes unless the flow switch opens or the power supply is disconnected. Digital Temperature Controller Operation The temperature controller is a two-stage controller with a liquid crystal display (LCD). Stage 1 is used for heating (factory set at 120F with 10F differential) and Stage 2 (factory set at 44F with 10F differential) is used for cooling. Follow the instructions below to change the settings if different temperatures are desired. There are three keys on the face of the control: SET, , . Step 1: To start programming, press the SET key once to access Fahrenheit/Celsius mode. The display will show the current status, either F for degrees Fahrenheit or C for degrees Celsius. Then press the up or down arrow key to toggle between F and C.

Bulletin 40-60 (October 2004) Page 33

Stage 1 (Heating) Step 2: Press the SET key again to access the stage 1 setpoint. The LCD will display the current setpoint and the S1 annunciator will be blinking on and off to indicate that the control is in the setpoint mode. Then press either the up arrow key to increase or the down arrow key to decrease the setpoint to the desired temperature. Step 3: Press the SET key again to access the stage 1 differential. The LCD will display the current differential and the DIF1 annunciator will be blinking on and off to indicate that the control is in the differential mode. Then press either the up arrow key to increase or the down arrow key to decrease the differential to the desired setting. Step 4: Press the SET key again to access the stage 1 cooling or heating mode. The LCD will display the current mode, either C1 for cooling or H1 for heating. Then press either the up arrow key or down arrow key to set at H1 for heating. Stage 2 (Cooling) Step 5: Press the SET key again to access the stage 2 setpoint. The LCD will display the current setpoint and the S2 annunciator will be blinking on and off to indicate that the control is in the setpoint mode. Then press either the up arrow key to increase or the down arrow key to decrease the setpoint to the desired temperature. Step 6: Press the SET key again to access the stage 2 differential. The LCD will display the current differential and the DIF2 annunciator will be blinking on and off to indicate that the control is in the differential mode. Then press either the up arrow key to increase or the down arrow key to decrease the differential to the desired setting. Step 7: Press the SET key again to access the stage 2 cooling or heating mode. The LCD will display the current mode, either C2 for cooling or H2 for heating. Then press either the up arrow key or down arrow key to set at C2 for cooling. SINGLE CHILLER SYSTEMS Single chiller systems can be controlled using the digital temperature controller inside the chiller or a thermostat. If the chiller will be controlled using the temperature controller, then no modifications are necessary to the wiring. The setpoint and differential temperatures can be adjusted using the steps explained above if settings other than the default values are needed. The chillers are wired so that the pump runs constantly when the switch is in cool or heat position. Figure 13a shows how to re-wire the system to turn on/off the pump with the room thermostat rather than running it all the time. To add this feature, a White-Rodgers (Steveco) Model 90-346 Two Pole Double Throw relay or equal must be added to the system as shown in Figure 13a. First, connect the compressor terminal (Y) and the Unico Air Handler terminal 7 relay coil. Then connect the air handler valve to one set of normally open contacts on the relay (usually terminals 1 and 3); this will open the valve and let water flow through the indoor coil when the system calls for heat or cool. The other set of contacts is used to power the chiller, including the pump. Connect terminals 4 (common) and 6 (normally open) of the relay to the transformer in the Unichiller as shown in Figure 13a. This method uses the selector switch to switch between cool and heat modes.

Bulletin 40-60 (October 2004) Page 34

THERMOSTAT White-Rodgers Thermostat Model 1F93-380 FAN HEAT COMPRESSOR POWER COMMON G W

CONTROL WIRING DIAGRAM CHANGES FOR UNICHILLER WITH PUMP CONTROL

UNICO SYSTEM AIR HANDLER Y 1 R 2 X 3

DPDT RELAY Steveco 90-340 Relay plus Enclosure (or equal) VALVE UNICHILLER (See Detail A) 1 4

B A

2 4 5

3 5

VALVE 6 7 Cut wire Detail A

B
BLUE OR

24 V
YL BLK

240 V

Transformer

EL00024a.CVX

Figure 13a: Wiring Schematic of Pump Control with a Two-Pole Relay

Another option is to control entire chiller operation from the thermostat. This method eliminates the use of the selector switch. The thermostat is used to turn on the pump and to switch between cool and heat modes. To eliminate the selector switch a double-pole, double-throw relay (Steveco 90-346 or equal) must be added as shown in Figure 13b. A heat pump thermostat (White-Rodgers Model 1F93-380 or equal) is used. Disconnect selector switch wires from terminals 2 (blue), 3 (black) and 9 (red) of the Unichiller. Connect terminal 2 (Unico Air Handler) to terminal 9 (Unichiller), terminal 6 (Unico Air Handler) to terminal 3 (Unichiller), terminal 7 (Unico Air Handler) to terminal 8 (Unichiller). Connect terminals 6 and 7 of the Unico Air Handler to the coil of the relay. Connect one set of normally open contacts of the relay to the indoor coil. Connect the second set of normally open contacts of the relay to terminals 2 and 3 of the Unichiller. Connect terminals B (reversing valve), R (power), Y (compressor) of the thermostat to terminals 2, 5 and 6 of the Unico Air Handler, respectively.

Bulletin 40-60 (October 2004) Page 35

THERMOSTAT White-Rodgers Thermostat Model 1F93-380 FAN HEAT REV. VALVE POWER COMMON COMPRESSOR G W B R X Y

Disconnect #1(Black Wire) and #2 (Blue Wire) of Selector Switch UNICO SYSTEM AIR HANDLER 1 2 3 4 5 6 7 1 2 3 4 5 6

Disconnect #3 (Red Wire) of Selector Switch

UNICHILLER-RC TERMINAL BLOCK

VALVE

3 5

6 DPDT RELAY Steveco 90-340 Relay plus Enclosure (or equal)

VALVE (Indoor Coil)

EL00085a.CVX

Figure 13b: How to Control the Unichiller-RC with Thermostat

MULTIPLE CHILLER SYSTEMS Two Chiller Systems without Stage Controller (Special Case) Although the best method of staging two-chiller systems is using a stage controller, it can also be accomplished by selecting the proper differential setpoints. Both chillers must be set at different differentials but both must be above 10F to prevent short cycling. For example, a two-chiller system with a 3-ton and a 5-ton can be set as follows: Both cooling temperatures set at 42F, 3-ton differential set at 12F and 5-ton differential set at 10F. Two or More Chiller Systems with Stage Controller When installing multiple chillers, use a multiple stage controller. Currently, the most common and readily available stage controllers allow for staging in either cooling or heating mode but not both. Therefore, if you want to stage both heating and cooling modes, you need two stage controllers: one for cooling and one for heating cycle. The multiple stage controller replaces the liquid chiller controller in the unit. The diagrams in this manual require that the chillers be wired for constant pump operation. If you would also like to stage the chiller pumps with the stage controller, contact Unico Customer Service at 800-527-0896.

Bulletin 40-60 (October 2004) Page 36

For up to four-stage control, a controller such as Heat-Timer SQ Series/SEQ-4 (contact Heat Timer for availability) or equal is recommended. The wiring schematic for this controller is shown in Figure 14. Please note that the unused stages must be switched off. Figure 14 shows how to wire a four-stage controller for constant pump operation. Details A and B in Figure 14 show the changes in the internal wiring of the chiller. Disconnect and remove the digital temperature controller (DTC) from the chiller (shown in Detail B). Connect the cooling stage controller to terminal 6 of the heat relay and to terminal 6 of the terminal block. Connect the heating stage controller to terminal 4 of the heat relay and to terminal 6 of the terminal block. Each Unichiller is connected to a different stage. Install the sensors of each stage controller on the systems main pipe.
CONTROLLER WIRING (COOLING) CONTROLLER WIRING (HEATING)

Main Pipe
Heating Sensor Cooling Sensor
A UX

SEQ-4

SEQ-4

Unused stages must be switched off

Unused stages must be switched off

Stage A
NO C C NO

Stage B
NO C C NO

Stage C
N O C C NO

Stage D
N O C C NO

Stage A
NO C C NO

Stage B
NO C C NO

Stage C
NO C C NO

Stage D
NO C C NO

A UX

Ground Ground

115V, 60Hz Input from separate branch ckt

115V, 60Hz Input from separate branch ckt

A C

UNICHILLER (See Detail A)

To additional device I.E. Secondary pump, combustion air damper, etc. To additional device I.E. Secondary pump, combustion air damper, etc.

UNICHILLER (See Detail B)

To additional device I.E. Secondary pump, combustion air damper, etc. To additional device I.E. Secondary pump, combustion air damper, etc.

CHILLER INTERNAL WIRING Detail A 4 6

Heat Relay

DISCONNECT DTC Detail B

B
5

A
DTC
COOL

6 C

RHEAT

2 4 C COOL C NO

5 6

RHEAT

2 4 HEAT C NO

HEAT NO NO

HPS

HPS

Terminal Block

C 1 2 3 4 56 7 89 Disconnect digital temperature controller and connect the stage controllers as shown
EL00037b.CNV

Figure 14: Wiring Schematic of a Four-Stage Controller With Two Stage Controllers & Constant Pump Operation

RE-LOCATING SELECTOR SWITCH There is a three-position selector switch on the unit that is used to switch between off, cool and heat modes. This switch can be re-located to a more convenient location such as the basement or the utility room of the house. To re-locate the switch, simply disconnect all switch wires from the terminal block (terminals 2, 3 and 9) of the Unichiller. Remove the switch from the unit. Replace the existing wires with thermostat wires long enough to extend to the new location. Connect the new wires to the terminal block. Place the switch on an enclosure box and mount as desired. Close the switch opening on the unit with a cap.

Bulletin 40-60 (October 2004) Page 37

LOW AMBIENT OPERATION To operate the chiller at outdoor temperatures below 65F (18C), install a low ambient (fan cycle) control and replace the existing 40-80 psig low pressure switch (A00703-001) with a 20-40 psig low pressure switch. This will allow operation down to 20F (-7C) outdoor temperature. A wind guard may be necessary for operation at windy conditions. Figure 15 applies to Ranco Fan Cycle Control MPF-7009 or equal installed to UnichillerRC. The fan cycle control will shut down both of the fans to maintain the head pressure. The fan cycle control opens when high pressure refrigerant side is at 190 psig (1310 kPa) and resets at 275 psig (1896 kPa). Install the switch on the high pressure refrigerant side.

Install a single-pole, double-throw relay (White-Rodgers 90-380 184-919 or equal) inside the UnichillerRC control box next to the terminal block. Disconnect the fan motor lead connecting to the T1 terminal of the contactor and connect it to one of the normally closed contacts and one of the normally open contacts of the relay. Then connect one of the low ambient controller leads to the other normally closed contact of the relay. Connect the other lead of the low ambient control to terminal T1 of the contactor. Connect the other normally open contact to T1 of the contactor. Connect the relay coil contacts to terminals 8 and 9 on the terminal block.
UNICHILLERRC - LOW AMBIENT CONTROL WIRING C Compressor
Fan 2 (Defrost Timer Board) Low Ambient Control

L1 L2

T1 CON T2

Terminal Block

1 3

2 4

5 6

SPDT (White-Rodgers 90-380 184-919 or equal)

Figure 15: Wiring Schematic of a Low Ambient Control Kit Both fans on/off

EL00026b.C NV

Bulletin 40-60 (October 2004) Page 38

TROUBLESHOOTING The following table is to be used for troubleshooting problems that may occur with the chiller. This table should be used only if there are no modifications to the controls, such as the addition of a low ambient control.
Table 16a: Unichiller Troubleshooting Chart - Main

Problem

Probable Cause No power. Pump does not stay on. No water in the system.

Remedy Check power coming in to the unit. See pump troubleshooting. Put water in the system. Adjust the temperature controller set point (no lower than 38F for cooling, no higher than 125F for heating). Check continuity of the switch. If faulty, replace. Check the operation of the temperature controller. If faulty, replace. Check for air or debris in the system. Remedy Check for a refrigerant leak, inoperative thermal expansion valve, low liquid solution control setting, low ambient operation, or low liquid solution flow. Check for a dirty condenser, inoperable fan motor(s), or the recirculation of condenser air. Remedy Purge the air in the system by opening the vent plug on the pump. Install auto air vent. Check pipe sizing and operation of the pump. Check continuity of the flow switch. If faulty, replace. Remedy Check for cracked pipe or loose fittings. Repair, if necessary.

Unichiller is not cooling or heating.

Water temperature set point is too high/low. Faulty switch. Faulty temperature controller.

Unichiller shuts down completely (including the pump). Problem

Open flow switch (Liquid solution is interrupted or air in the system). Probable Cause

Table 16b: Unichiller Troubleshooting Chart - Compressor

Compressor and fan motors shut down before the set water temperature is reached.

Open low-pressure switch.

Open high-pressure switch.

Table 16c: Unichiller Troubleshooting Chart - Pump

Problem Pump shuts off shortly after the power is applied from the circuit breaker and switch turned to cool or heat position.

Probable Cause Air in the system or lack of water in the system. Low water flow. Faulty flow switch.

Table 16d: Unichiller Troubleshooting Chart - Other

Problem Air in the system or lack of water in the system.

Probable Cause Water leak.

Bulletin 40-60 (October 2004) Page 39

SERVICEABILITY Fan guards must be taken off to service the fan blades or motors:

Side panels must be taken off to access the compressor-pump compartment:

Top panel and upper side panel must be removed to access the control panel:

MAINTENANCE The following are the periodic maintenance requirements of Unichillers: Clean the coil surfaces at least twice a year or when visibly dirty. The strainer should be checked after the first 48 hours of operation after installation for any debris. Unless the water is drained from the system, there is no need to check the strainer periodically because this is a closed system. If there is enough freeze protection in the water lines, there is no need to drain the system during winter. Unico recommends using propylene glycol for freeze protection. Please see the Table 9 for the required percentages of propylene glycol. The Unichillers are pre-charged with R-22. Therefore, the refrigerant lines should not be broken into unless approved by the manufacturer.

Bulletin 40-60 (October 2004) Page 40

REFERENCES 1. Pump Manufacturer Pump Performance Data. 2. Unico, Incorporated - Bulletin 20-20.3 and Bulletin 30-10. 3. Kitec Pipe Performance (IPEX Inc.). 4. Bell & Gossett System Syzer Calculator. 5. REHAU Pipe. 6. 2001 ASHRAE Fundamentals, F35.6.