Design Assistance Manual

Manufactured ByEnergy Saving Products Ltd.

StandardESP 104.03

ModelsHV - 50/51/52HV - 70/71HV - 100/101HV - 140

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Table of ContentsPreface .......................................................... 2

System DesignVents

Locating ............................................................ 3Kick Spaces ..................................................... 3Linear Grills ...................................................... 4Drilled Outlets ................................................... 4

Plenum Runs on Ceiling .............................. 5Plenum Runs on Sidewall ............................ 5

Fan Coils Placement ........................................................ 5

Counter Flow Position .................................. 6Hi-Boy Position ................................................ 6

Horizontal Position ....................................... 6Clearances ....................................................... 6

Plenum Duct Location ............................................................ 6Connectors ....................................................... 7Elbow and Tee Placement ................................ 7

Branch Tees ................................................. 7Bullhead Tees .............................................. 7

Insulation Sleeve .............................................. 7Space Saver Take-Offs .................................... 7Duct Reductions ............................................... 8

Branch DuctBranch Duct ..................................................... 8De-Rating Values ............................................. 9

Refrigerant Modules Refrigerant Module (RCM/RM) ........................ 9

Piping the RCM/RM ..................................... 9Pipe Sizing ................................................... 9

Refrigerant Pre-Piped Module (RPM) .............. 10Water Coil Module (WCM/WM) ........................ 10

Piping the WCM/WM .................................... 10Hot Water Add-on............................................. 10

Electrical Strip Heater...................................... 10Specifications .................................................. 10

Secondary Drain Pan .................................. 10

Return Air Duct Sizing ....................................................... 11Location ............................................................ 11Transitions ........................................................ 11Return Air Base ................................................ 12

Dimensions .................................................. 12Filter Rack ........................................................ 12

Dimensions .................................................. 12Filters ................................................................ 12

Third Party Options Fresh Air Make-Up ........................................... 13Humidifier ......................................................... 13Fire Stopping ................................................... 13

Hi-Velocity and RadiantCombination Systems ...................................... 14

Low Temp Water Systems ............................ 14

System SelectionHeat Loss/Gain ................................................ 14Unit Selection ................................................... 14Average BTUH per outlet ................................. 15

Heating ........................................................ 15Cooling ........................................................ 15

Difference in Number of vents(heating/cooling) .......................................... 15

House Drawing with Data ............................ 16

System LayoutVent Placement ............................................... 17Drawing the plenum ......................................... 17Drawing Branch runs ........................................ 17

Min & Max lengths ....................................... 17

House Layout ................................................. 18

Appendix AFan Coil Specifications ..................................... 19

Appendix BProduct Specifications ..................................... 20

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Hi-Velocity Fan Coil Systems

Fan coil units specified in this section shall be designed as a closed loop hydronic fan coil system, with published BTUH ratings with entering water temperatures set between 110°F and 190°F. System shall allow for heating, TX or chilled water cooling, and heat pump applications with electric coil back-ups. Entering water temperature and BTUH outputs shall match performance listed in Table 01.

The fan coil units shall be designed, rated and approved by CSA/UL, and shall conform to applicable ASHRAE, ARI and DOE standards.

Minimum of 8 outlets per ton cooling. See Table 02 for minimum and maximum per fan coil size.

The fan coil units shall have pre-wired controls consisting of a 24V transformer and printed circuit board. Circuit board shall be capable of providing both heating and cooling. Motors shall be 115/1/60 with published amp draws. The fan coil unit shall have speed controls for both constant fan and heating operation (HV Series only).

Sweat water connections are 1⁄2” Cu for the HV-50, 3⁄4” for the HV-70 and HV- 100, and 1” on the HV-140. All lines should be piped so as not to restrict use of the access panels, filter section, or electrical enclosure. When the potential for gravity flow of the hot water exists, spring check valves may be needed on both the supply and return lines.

Sound data documented at 30 dba at each outlet using maximum number of outlets specified, and 40 dba if minimum number of outlets are used.

The fan coil unit can be located in a Horizontal, Hi-boy or Counter-flow position and can be suspended from the ceiling or placed directly on the floor. Location of the fan coil will vary depending on the following: length of duct runs, usable floor space, serviceability and accessibility to unit, minimizing structural changes, location of heating/cooling source, and available space in mechanical room.

The main supply duct shall be located either along the main beam(s) in the basement or in the attic space depending on location of fan coil. The supply duct shall be sealed for leaks and covered with R8 insulating sleeve if duct is located in an unconditioned area. Selection of main plenum location shall ensure that the 2” flex duct length is minimized with a maximum run length of 25 ft. Ducting layout to be matched as per the design of Energy Saving Products Ltd., or pre-approved equal.

Quality AssuranceFan coil units shall be a total indoor air quality system

complete with heating, cooling, air filtration, and possibility of humidity control and fresh air make up. The fan coil must be factory manufactured, assembled and tested.

All equipment furnished under this specification shall comply with the following standards:

ASHRAE American Society of Heating,Refrigerating and Air-ConditioningEngineers

ARI Air-Conditioning and Refrigeration Institute

CSA Canadian Standards Association

CE European Conformity

DOE Department of Energy

UL Underwriters Laboratories

The Hi-Velocity Systems are not to be used as temporary heating/cooling during the construction of the structure. If used in this capacity all warranties will be null and void.

ItemBTUH

@ 190ºF EWT

BTUH

@190ºF EWT

KwElectrical

Strip

TX CoolingMBH

HV-50/RCM-50HV-52/RCM-50HV-70/RCM 70HV-100/RM-100HV-140/RM-100

56,20055,10079,700113,400150,400

44,40041,60062,90086,300113,800

5 - 15 KwN/A

5 - 18 Kw5 - 23 Kw

N/A

18 - 2418 - 2430 - 3642 - 60

60

HV - 51 ratings same as the HV - 50HV - 71 ratings same as the HV - 70HV - 101 ratings same as the HV - 100

Table 01

Table 02

Model(1) Ø” Supply

Air& Max Length

ReturnAir

Min #Outlets

Max #Outlets

CFM @250/ton

HV-50/51

HV-70/71

HV-100/101

HV-140

8” Ø - 70’

8” Ø - 80’

10” Ø - 100’

10” Ø - 120’

12”

12”

14”

16”

14

20

30

40

20

29

45

50

550

750

1100

1250

HV-52

Medium

High

8” Ø - 50’

2 x 6” Ø - 50’

10”

12”

8

12

14

19

375

550

(1) Ø - Plenum diameter

Please read the ENTIRE manual before beginning installation as this will help avoid mistakes that may cost time and money.

Maximum length is from the unit to the supply run end cap. More than one run per unit is allowable.

Fan coils to be located indoors, however, attic, crawl space and garage conditions are fully acceptable.

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System Design

The following section is basic information needed for the designer. If you would like to learn more about installing the Hi-Velocity System, please read the Hi-Velocity Installation Manual.

VentsWith the venturi effect of the Hi-Velocity system, you

have more options in vent placement. Each vent has an effective throw of 18’ (Fig. 01) and causes the air to constantly circulate. This allows for vent placement in floors, ceilings, or walls. Fig. 01 illustrates the venturi effect of a single outlet.

The constant circulation is very important to maintain room comfort. Do not install vents under/beside/on-top of objects that may hamper the cone of influence from circulating the room air.

Locating Vents

Outlets do not have to be located on an outside wall. Due to the venturi action of the Hi-Velocity System, the air in the entire room is gently circulated at all times. The outlets should be located six inches on centre from any possible obstruction (Fig. 02).

Fig. 01 - Cone of Influence

Proper location is critical to the operation of the Hi-Velocity System for optimum home comfort. The outlets should be located where it is considered to be a “low traffic area”. Typical areas are in the corner of a room, or to the side of a window or door. When the vents are properly located, the home owner can expect to have a nearly draft free home.

Vent placement in outside walls of the structure should be avoided. Flexible duct that is run in outside walls may receive a substantial heat loss/gain. This can result in a higher operating cost for the structure while delivering an inferior air quality.

Installing Vents in Kick Spaces

In kitchens and bathrooms, however, it is hard to find a “low traffic area”, so it is recommended to locate the vents in the kick space under the counters. Our Vent plates have a 4” and 5” diameter, which may not fit in all kick spaces without trimming. This can easily be done by trimming the top and bottom of our vent plate so it fits.

By locating the vents in this position, there will now be horizontal airflow. Caution should be exercised when locating vents in the horizontal position. Avoid placing vents directly below sinks or other locations people will be for extended periods of time.

Fig. 02 - Six inches on center

6”

6”

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Linear GrillsInstallations in areas that have a high heat loss/gain

require multiple vents. Multiple vents can be installed into linear grills for a more esthetically pleasing look. Installing in a high sidewall/ceiling or floor makes little difference (Fig. 03).

When installing multiple vents into linear grills, the vents must be a minimum of 6” on center from each other (Fig. 05). Same rules apply for vents in linear grills as a single outlet installation; see locating vents for more information on vent placement.

Fig. 04 - Straight vanes only

Fig. 05 - 6” Apart on center

Installing the vents around the room will allow for the room air to mix. This will give the room a more even air temperature and better distribution.

Drilled OutletsCaution must to be used when not using the 2” flexible

duct, the air velocity from the drilled outlet may create noise. Drilled Outlets CAN NOT be installed in a residential structure; too much noise is generated from the outlets. In commercial areas with large ceilings the sound can be absorbed by the room or is not a concern because of the ambient noises.

Drilled outlets are commonly used to supply a large area with heating and cooling. Drilled outlets can also be used to create a pressurized air curtain, for bay doors, or large openings to the outside environment. When drilled outlets are used with the Hi-Velocity System a few points to remember:

When multiple 1” or 2” holes are used, they need to be a minimum of 6” apart on center (Fig. 06).

One 11⁄4” drilled hole is equivalent to a single 2”x10’ AFD kit (2” Rough-In Boot attached to a 10’ piece of flex duct). With the 11⁄4” drilled outlet the throw from the outlet is up to 18’.

One 2” drilled outlet is equivalent to two - 2”x10’ AFD kits (2” Rough-In Boot attached to a 10’ piece of flex duct). With the 2” drilled outlet the throw from the outlet is up to 30’ in distance.

Using drilled outlets larger than 2” is not recommended; with too large of an opening in the main plenum the static pressure may drop to an unacceptable level.

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6”

6”

A Straight Vane vent grill is the ONLY type of linear grill that can be used with the Hi-Velocity System (Fig. 04).

Fig. 03 - Linear Grills

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Fig. 06 - 6” Apart on center

Plenum Runs on CeilingWhen drilled outlets are used in a ceiling install, drill the

outlets at a 45° angle to properly circulate the room air (Fig. 07).

Plenum Runs On SidewallFor sidewall installations the outlets are drilled parallel

to the floor (Horizontal airflow). When the vents are in this configuration, they can be used to create a pressurized air curtain.

Fig. 07 - Airflow 45° angle to floor

Fig. 08 - 6” airflow parallel to floor

Fan Coils

Hi-Velocity Systems Fan coils are manufactured with a direct drive permanent lube motor that is mounted within the blower. All Hi-Velocity Systems fan coils are single side access. The blower assembly can easily be slid out by removing the three mounted bolts that attach it to the center plate. In some instances, the electrical box may need to be removed.

Placement

When locating the fan coil keep these points in mind:

Serviceability and access to the unit.

Maximizing usable floor space.

Location of heat/cool source to fan coil.

Quite often, the best location for the fan coil unit is suspended from the ceiling of the mechanical room, in the Horizontal position (Fig. 11). This will allow for more floor space in the room, and will minimize the duct work needed to connect to the fan coil unit.

The fan coil can be installed in many different configurations. It can be located in a Hi-Boy, Counter flow, or Horizontal position. In the Hi-Boy position, the supply air is delivered from the top of the unit (Fig. 09) When placed in the counter flow position, the supply air delivery is from the bottom of the unit (Fig. 10).

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Fig. 09 - Hi-Boy

Fig. 10 - Counterflow

Fig. 11 - Horizontal

Clearances

Clearance is only needed on the access side of the units. However, ensure that there is a small space between the unit and any other surface to prevent vibration transfer. In order to maintain and service the fan coil unit, the minimum clearances required on the access side are (Table. 03).

Table 03 – Fan coil clearances

Unit InchesHV – 50/51/52 18”HV – 70/71 22”HV – 100/101 29”HV – 140 29”

Add an additional 4” for Electric Strip Coils

Plenum Duct

LocationWhen locating the plenum duct, one of the main factors

to consider is the integration of the duct work into the structure. The main supply duct can be located along the main beam(s) in the basement (Fig. 12).

Fig. 12 - Basement installation

Min. 18”

The main plenum can also be easily installed in the attic space. (Fig. 13)

Fig. 13 - Attic Installation

If the unit is installed in the attic, make sure that all ducts in the attic are insulated with a vapor barrier (All A/C systems main plenums need to be insulated and vapour barriered). This includes the Branch Take Off and the vent Rough-In Boot. If the duct work is run above the attic insulation, an extra insulation sleeve may be needed. Check your local building code for the ruling in your area.

For any duct runs over 75% of the maximum allowable plenum length (Table 02), it is recommended to insulate the main plenum. Insulating the main plenum will cut down on your duct loss, and form a vapor barrier. The attic insulation should be placed over all Hi-Velocity System ducts to further reduce any duct losses.

18”

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Fig. 14 - Connectors

1. Tee Connection

2. Elbow Connection

3. Reducers

4. End Cap

5. Straight Connection

Elbow and Tee PlacementElbows and tees must not be placed any closer

than 18” from supply outlet on the air handling unit. A significant loss of airflow can result if elbow or tees are installed closer than 18”. Fig. 12 and Fig. 13 illustrate a proper install with at least 18” of straight plenum after the unit supply outlet. Fig. 15 shows the sigma velocity profile of the first 18” of the main plenum and why it’s important to allow the system to equalize air flow.

Fig. 15 - Sigma velocity profile

If elbows, tees, or Branch Take-Offs are placed closer than 18” you may lose up to 30% of your airflow as illustrated in Fig. 15.

UniformVelocity

Point

10% Loss

20% Loss

30% Loss

18”

Branch TeesWhen branch tees are used, the plenum split is to be a

70/30 main/branch split (Fig. 16).

Bullhead Tees

Bullhead tees are to be maintained as close to a 50/50 split as possible, with a maximum 60/40 split (Fig. 17). For the best system performance, keep the number of elbows and tees to a minimum.

Insulation Sleeve

Any time the duct will be run in an unconditioned space (attic or crawl space) it must be insulated with a vapor barrier. It’s also recommended to vapor barrier runs that exceed 75% of the total allowable distance (Table 02).

Space Saver Supply Take-Offs

The Space Saver model is the same as other Hi-Velocity Systems with the exception of the supply air take-offs. The Space Saver was designed for closer main plenum take-offs with more take off points. The Space Saver comes with 5 available supply outlet locations. The unit consists of four 6” supply outlets, along with a single 8” outlet at the end/top of the unit (Fig. 19).

When the 8” supply outlet is used, no elbows or tees shall be placed any closer than 18” from the top side of the air handling supply outlet (8” only Fig. 18).

Fig. 16 - Branch Tee, 70/30 split

Fan Coil

30% FLOW 6 Vents

70% FLOW

14 VentsEXAMPLE20 VENTS18” Min.

Fig. 17 - Bullhead Tee, 50/50 split

Fan Coil EXAMPLE20 VENTS

50% FLOW(+/- 10%)10 Vents

50% FLOW(+/- 10%)10 Vents

18” Min.

Main Plenum ConnectorsThere are five types of connections that are possible

with the Hi-Velocity System.

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Fig. 18 - Space Saver take-offs

8” Only

Any Two 6” take-offs, no 8”

A significant loss of airflow can result if installed closer than 18” (Fig. 15). When using the top 8” supply outlet only that outlet may be used (Fig. 18).

Fig. 19 - Space Saver take-offs

When using the 6” outlets, a combination of two 6” outlets may be used at a time, with no more than two 6” take-offs used (Fig. 18). When the 6” outlets are used, elbows and tees may be closer than 18” from the outlet

Duct ReductionsIn some installations, it is necessary to reduce the

size of the main plenum. Caution must be used when reducing plenum size, since smaller ducts can handle less number of outlets. The Branch Take Off’s easily form to ducts in the 6” to 8” range; extra care must be taken with smaller sized ducts to ensure a proper air seal. For tee reductions, keep the tee to the full duct size, reducing only after the tee. Keep the length of the smaller duct sizes to a minimum, since the friction loss is much higher.

Branch Duct

With both the Main Plenum and Rough-In Boot located, there is now only the connection of the two. This is done with the two inch flexible branch duct. Keep in mind that the minimum duct length is 10 feet (5’ with the Builders and Space Saver), with a maximum length of 25 feet (15’ for Space Saver). Branch duct runs should be kept as short as possible to maximize the airflow through these runs. Energy Saving Products supplies the 2” flexible duct in three different configurations:

2” x 10’ AFD (Assembled Flex Duct)2” x 15’ AFD (Assembled Flex Duct)2” x 25’ UFD (Unassembled Flex Duct)

(Builders and Space Saver Systems may use a 5’ AFD)

The 2” AFD comes complete with the necessary components for one complete ten foot or fifteen foot branch run. The 2” UFD is to be used only to extend these runs if needed.

If extending branch runs longer than the minimum reference Table 05 for adjustment values.

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Table 04 – Duct Reduction

Duct Size # of Vents Max. Length4” 4 30’5” 6 40’6” 12 50’7” 19 60’8” 29 70’

10” 50 100’

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Table 05: De-rating Values

HV and Builders Series

Tubing LengthAdjustment Factor

10’0%

15’10%

20’20%

25’35%

Space Saver Series

Tubing LengthAdjustment Factor

5’0%

10’10%

15’20%

20’35%

Refrigerant Modules (RCM/RM)The cooling coil comes as a module and must be

installed in the vertical position on the return air side of the fan coil.

Refrigerant modules come with two L mounting brackets, thermal expansion valve, site glass, two access ports, and an external freeze stat. Figure 20 shows an installed coil assembly and how each piece is connected.

Fig. 20 - Coil Assembly

1

2

3

9

10

1112

5

6 8

7

4

14

13

Evaporator Coil

1) Liquid line

2) Site glass

3) High side access port

4) Adjustment stem cap

5) Superheat adjustment stem

6) Thermal expansion valve (TX)

7) Refrigerant distributor

8) Distributor tubes

9) External equalizer line

10) Suction line

11) Anti-ice control

12) Low side access port

13) TX capillary tube

14) TX sensing bulb

R series modules can be used on R-410A condensers; if R-410A refrigerant components are used. All Energy Saving Products R series modules are shipped with R-22 refrigerant components. R-410A is a specialty order and must be stated at time of purchase.

Piping the RCM/RM

Refrigerant grade pipe and fittings are only to be used with Hi-Velocity Systems. Plumbing fittings may contain wax or other contaminants which are detrimental to the proper operation of the system. Insulate the suction line with 3/8” insulation such as Armaflex. In high heat areas, 1/2” insulation may be needed. If the lines are run in an area where temperatures could exceed 120°F or runs longer than 50’, then the liquid line may need to be insulated as well. Support the pipe every 5 feet, or whatever local code states.

Run the pipes in the most direct route possible, taking into account structural integrity and building details. If the evaporator is located above the condenser, slope any horizontal runs toward the condenser. If the condenser is located above the evaporator, a P-trap must be installed at the bottom of the vertical riser. For long vertical risers, additional P-traps must be installed for every twenty feet. For lines running over 50’, a suction line accumulator must be installed. Lines running over 100’ are not recommended.

Pipe SizingTables 06 and 07 contain line sizing information for the

liquid and suction lines.

The sizes given in the above tables are only for general reference, if the condenser manufacturer requires a different size than specified in Table 06 and Table 07, their sizing shall be used whenever a discrepancy occurs.

Table 06 – Liquid Line sizes

TonsDistance 1 11⁄2 2 21⁄2 3 31⁄2 4 5

1’–25’ 1⁄4 1⁄4 5⁄163⁄8 3⁄8 3⁄8 3⁄8 1⁄2

26’–50’ 5⁄165⁄16

3⁄8 3⁄8 1⁄2 1⁄2 1⁄2 1⁄2

51’–75’ 3⁄8 3⁄8 3⁄8 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2

76’–100’ 3⁄8 3⁄8 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2

Table 07 – Suction Line sizes

TonsDistance 1 11⁄2 2 21⁄2 3 31⁄2 4 5

1’–25’ 5⁄8 5⁄8 3⁄4 3⁄4 3⁄4 7⁄8 7⁄8 1

26’–50’ 5⁄8 3⁄4 3⁄4 3⁄4 7⁄8 7⁄8 11⁄8 11⁄8

51’–75’ 3⁄4 3⁄4 7⁄8 7⁄8 11⁄8 11⁄8 11⁄8 11⁄8

76’–100’ 3⁄4 7⁄8 7⁄8 11⁄8 11⁄8 11⁄8 11⁄8 11⁄8

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Refrigerant Pre-Piped Module (RPM)The RPM comes pre-piped with the coil assembly; the

coil assembly is shown in Fig. 20. With the RPM the Liquid and Suction line are the only brazing that need to be done at the fan coil. For charging and brazing, remove the front access panel of the RPM (Fig. 21). With the access panel removed the coil assembly will be accessible. Wet rag the liquid and suction line (or use a heat dissipating paste) to ensure no overheating occurs to the pre-piped coil assembly.

Install the RPM with the same procedures used per RCM, omitting the coil assembly as it has already been pre-piped.

Fig. 21 - Remove front access panel

Water Coil Module (WCM/WM)

The water coil comes as a module and must be installed in the vertical position on the return air side of the fan coil. The WCM/WM come Supplied with two L mounting brackets for connection to the fan coil. For WCM/WM dimensional information and sweat water connection sizes refer to Appendix B.

Piping the WCM/WMWhen the potential for gravity flow of the hot water

exists, check valves may be needed on both the supply and return lines. All lines should be piped so as not to restrict access to the front panels, filter section, or electrical enclosure. Size your supply and return lines according to Table 08.

Fig. 22 - Secondary drain pan

P-Trap

Secondary drain pan

Electrical Strip Heater (ESH)

The Electrical Strip Heater slides into the fan coil, on the supply side of the blower (Appendix B - Product Sizing).

Use only wires suitable for 75ºC; wires shall be sized according to local electrical code.

Use only class 2 wiring for the Control Circuit connections between the heater terminal 1, terminal 2 and the zone valve terminals.

Table 09 – Electrical Strip Heater specifications

KwVolts/Phase

# of Feedersand heater

Circuit Breakers

5 240/1 1 x 20.8 1 x 30A

10 240/1 1 x 41.6 1 x 60A

15 240/1 1 x 20.8 1 x 41.6 1 x 30A 1 x 60A

18 240/1 1 x 41.6 1 x 41.6 1 x 60A 1 x 60A

20 240/1 2 x 41.6 2 x 60A

23 240/1 2 x 47.0 2 x 60A

Hot water Coil Add-on (HCA)The Hot water coil add-on is easily installed in the

Hi-Velocity System. With heating, condensate is not a consideration and the coil can be mounted on the supply side of the blower.

With the removal of the front panels, the HCA can be slid in place on the supply side of the blower (Appendix B - Product Sizing).

Electrical Strip Heater (ESH)Some building codes call for a secondary drain pan

under the entire unit (Fig. 22). Any installation that has the potential of property damage due to condensate must have a secondary drain pan installed. If the unit is installed in a high heat and/or high humidity location, extra insulation around the unit casing may be required. This will prevent excessive condensate from forming on the outer surface of the casing.

Table 08 – WCM/WM pipe sizing

Zone BTUHHeat loss

Pipe Sizeup to 40 feet

Pipe Size40 – 100 feet

0 - 35,000 5⁄8” 3⁄4”

35,001 - 70,000 3⁄4” 1”

70,001 - 140,000 1” 1 1⁄4”

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Fig. 24 – Return air transition

A round or square return air duct can be used; they must be sized for the Hi-Velocity Systems according to table 10. Before the return air can be attached to the transition (Fig. 24), the first five feet (from the fan coil) is to be acoustically lined for sound absorption.

Fig. 23 - Return air location

LegendRA - Return air

Note:

DO NOT cut past the center plate or electrical box (Dim A & B).

Model HV-100 and HV-140 CANNOT use return air “C” (RA-C).

This drawing is NOT to scale.

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Return AirThe return air duct is not supplied with the

Hi-Velocity System. It is to be supplied and installed by the contractor. The return air and fresh air make-up ducts are to be installed according to local building code.

The first five feet of the return air duct from the air handling units is to be acoustically lined for sound absorption. This only applies on short return air duct work of less than 10 feet. For traditional house return air using a combination of return air metal duct and joist liners this does not apply.

Duct SizingThe return air is to be sized on a 0.15 static pressure as

compared to 0.10 static pressure for conventional forced air systems. The maximum length for an individual return air duct is fifty feet.

Table 10 – Return Air duct sizes

Unit Round Duct Square Inches

HV-50/51/52 H/BUHV-70/71 H/BU

12” 113

HV-100/101 H/BU 14” 154

HV-140 H/BU 16” 201

When sizing the return air ducts, keep in mind that if they are too small they can create noise, but if they are too large, the fan coil cannot build up proper pressure. Table 10 has recommended return air sizes for round and rectangular ducts. A variance of plus/minus 20% is allowable for sizing return ducts that connect to the Hi-Velocity Systems unit.

It is recommended to install a grill that is 10 - 20% larger than specifications require, this will ensure that there is no air velocity noise at the grill. Where allowed by local codes, a single return air grill may be used. When using flexible duct for return air, use one duct size larger due to the higher friction loss.

Return LocationFig. 23 shows the different locations the return air can

be installed on Hi-Velocity Systems. Table 10b contains the dimensions needed for the return cutout. All fan coils are shipped with a Return Air Cutout template; the template will guarantee maximum airflow across the coil.

Table 10b – Return air cutouts

Model A B C D

HV-50/51/52 H/BUHV-70/71 H/BUHV-100/101 H/BUHV-140 H/BU

3”3”3”3”

17”17”17”17”

10”15”22”22”

14”15”15”15”

HV-140 sizing based upon RCM Cooling Module

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Return Air Base (Optional)

Energy Saving Products manufactures a return air base with a built in filter rack that matches up to the fan coil units. The return air base comes complete with a one-inch filter and one-inch filter rack. The filter is a 3 medium filter approximately 14% efficient, and can be replaced with any aftermarket filter. All the Return Air bases come acoustically lined with half-inch sound absorbing insulation.

Filter Rack (Optional)

Also available from Energy Saving Products is a 3” Filter Rack, supplied with a one-inch 3 medium filter approximately 14% efficient, and can be replaced with any aftermarket filter.

Filters

Energy Saving Products filters are 1 inch thick, 3 medium filters approximately 14% efficient. Any after market filter may be used with both the Hi-Velocity Return Air Base and Filter Rack.

Table 13 – Filter Part Numbers

FR/RA-50/51 10050900050

FR/RA-70/71 10050900070

FR/RA-100/101 10050900100

FR/RA-140 10050900100

Fig. 25 – Return Air Design

Two 11⁄8” Rails (D) for fan coilPlacement and Filter Holder

11⁄8” Opening

AE

C

B

D

Table 11 – Return Air Base dimensions

A B C D E

HV-50/51/52 24” 181⁄2” 141⁄2” 11⁄8” 213⁄4”

HV-70/71 24” 181⁄2” 191⁄2” 11⁄8” 213⁄4”

HV-100/101 24” 181⁄2” 251⁄2” 11⁄8” 213⁄4”

HV-140 24” 241⁄2” 261⁄2” 11⁄8” 213⁄4”

Table 12 – Filter Rack dimensions

A B C D

HV-50/51/52 3” 18½” 14½” 11⁄8”

HV-70/71 3” 18½” 19½” 11⁄8”

HV-100/101 3” 18½” 25½” 11⁄8”

HV-140 3” 24½” 26½” 11⁄8”

Fig. 26 – Filter Rack Design

Two 11⁄8” Rails (D) for fan coilPlacement and Filter Holder

11⁄8” Flange(on each side)

11⁄8” Opening

AC

B

D

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Third Party Options

Fresh Air Make-Up

For areas that require fresh air make-up, a small intake may have to be installed. It is recommended to install an insulated flex duct, with a damper, into the return air plenum. The damper can then be adjusted to supply the exact amount of fresh air needed to meet local building codes (Fig. 27). This should be balanced to the exhaust air levels of the structure.

Install the fresh air duct to the side of the return air and if possible not directly into the air stream. As shown in Fig. 27, the fresh air duct has been installed more than 5’ away from the fan coil and before a 90º bend.

If too large of a duct is installed, the excess fresh air will increase system operating costs and decrease system performance.

Fire StoppingSome areas require a Fire Stopping device to stop

the spread of a fire and/or prevent the duct system from supplying oxygen to the fire. The Hi-Velocity System can be used in conjunction with several types of Fire Stopping devices.

With our Rough-In Boots, Metacaulk pipe collars work very well; figure 29 gives an illustration of a pipe collar used with the Rough-In Boot. Many options are available to the designer, if assistance is needed in product choice. Call our representatives at Energy Saving Products for technical advice.

Humidity ControlWhen a bypass type

humidifier is used, the humidifier can be mounted on the return air duct, and then a two inch take-off from the hot air side is run back (Fig. 28). DO NOT use any size larger than two inch, and be sure to install a summer shut-off, or it will create problems with the airflow. When installing a steam humidifier install on the return side of the unit.

Fig. 28 – Humidifier

Fig. 29 – Fire Stopping Devices

Lots of ChoicesPipe CollarsWrap StripsMechanical Shut offsCall ESP for Advice

••••

Fig. 27 – Fresh Air Make up

ExteriorIntake

Insulated Fresh Air Intake

AdjustableDamper

Not directly into the air stream, more than 5’ away from fan coil to allow fresh air to mix with the return air. A P-Trap should be installed to stop the migration of air.

P-Trap

18”

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Combination Hi-Velocity and Radiant

One of the benefits of using a hydronic system is the versatility that you have when designing the heating system. Radiant floor heating is an excellent system, but it does have limitations. You cannot have cooling, air filtration, and humidification with a straight radiant heating system. Similarly, sometimes a forced air system is not the only option available for a house, especially if it has a lot of ceramic tile or concrete floor areas.

In the sample house included, radiant floor heating would be unable to meet the requirements to heat the nook. With the Hi-Velocity System, we can heat this room, but would have an excessive number of outlets in a small area.

Fig. 30 - NookExample

Room: NookHeat loss: 8,326 BTUHNumber of Vents: 4

It is in rooms such as this that a hybrid system of both radiant heating and Hi-Velocity Systems would be the optimum system to provide comfort conditioning. This will provide the home owner with good indoor air quality, and warm floor comfort (not as effective if carpet is laid down).

A common approach to a hybrid system is to heat the basement with radiant tubing. The main floor and 2nd floor if applicable would be heated with the Hi-Velocity System. A few outlets can also be placed in the basement to provide air circulation, and supplementary heating if required.

Low Water Temperature Systems

When running Hi-Velocity Systems from a low water temperature system (eg. A hot water tank), care must be taken when designing and installing the system. Due to the lower water temperature there will be less BTUH’s and therefore a lower supply air temperature, it is imperative that the water temperature is known at the design stage. If possible the highest temperature setting should be used, and a water tempering valve installed for the domestic use. The higher water temperature will increase system efficiencies, and the water tempering valve will reduce the risk of scalding. Since some areas have specific regulations regarding combo systems, please check your local building code for details on water tank temperatures, tempering valves, and pump timers.

Due to the lower air temperatures, when running the ductwork in an unconditioned space, the main plenum must be insulated and vapour barriered. Extra insulation should also be used in order to maintain a reasonable leaving air temperature at the vents.

System Selection

Heat Loss/Gain

To size a Hi-Velocity System for a residence, it is necessary to have an accurate heat loss/gain done for the structure. This will ensure the proper equipment is used for cooling and heating.

A heat loss/gain is done for each room, which will give a total BTUH load for the structure.

Table 14 - Example Data for Fig. 31

Room Name BTUH Loss BTUH Gain

NookKitchenBathBed #1Bed #2Dining Rm.FoyerFamily Rm.Master BedM.Bath/WIC

8,3262,5391,1142,6673,8455,1094,1865,8599,3262,786

5,2331,688

6931,5922,1653,8022,1664,0016,0461,193

Totals 45,757 28,579

The design factors used to achieve this heat loss/gain are shown on Fig. 31.

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Unit SelectionWith the total load known for the structure, it is now

possible to select the proper Hi-Velocity unit (Appendix A or Table 01).

Table 15 – Selected fan coil

Selected fan coil:Entering Water TempHouse Heat Loss:House Heat Gain:Minimum Outlets:Maximum OutletsSelected Condenser

HV-70 H180°F45,757 BTUH28,579 BTUH20292.5 ton

Average BTUH per OutletOnce the unit has been selected, the average numbers

of outlets can be determined (Table 02 or Appendix A). To determine the average number of vents, the minimum is added to the maximum and divided by two.

Example:

(Min Outlets (20) + Max Outlets (29)) / 2 = 25

With the average number of vents known it is now possible to determine the average BTUH output per vent. Dividing the average number of outlets into the fan coil output (Table 02 or Appendix A) will give an average BTUH output per vent.

Example:

BTUH per Outlet for HEATING

73,800 BTUH / 25 = 2,920 BTUH/OUTLET(2,952 BTUH delivery per outlet for Heating)

BTUH per Outlet for COOLING

30,000 BTUH / 25 = 1,200 BTUH/OUTLET(1,200 BTUH delivery per outlet for Cooling)

The BTUH per outlet is then used to figure out how many outlets are required for each room. As an example, here is a room by room load calculation for the house plan included (Fig. 31).

Table 16 – Number outlets per room

Room NameBTUH LOSS

BTUH GAIN

Numberof Vents

NookKitchenBathBed #1Bed #2Dining Rm.FoyerFamily Rm.Master BedM.Bath/WIC

8,3262,5391,1142,6673,8455,1094,1865,8599,3262,786

5,2331,688693

1,5922,1653,8022,1664,0016,0461,193

4212232351

Totals 45,757 28,579 25

A room (Nook) that has a heat loss of 8,326 BTUH and a heat gain of 5,233 BTUH will need 4 vents.

Example:

4 x 2,952 BTUH = 11,808 BTUH(11,808 > 8,326 Heating requirements satisfied)

4 x 1,200 BTUH = 4,800 BTUH(4,800 < 5,233 Cooling requirements not satisfied)

The heating checks out but the cooling doesn’t in this example. We allow a 0.1 variance on vent checks, which gives a little leeway with vent placement. Also with the kitchen being an adjoining room with an extra 712 BTUH it will help the nook maintain the desired temperature

Table 17 - System Check

Heating Cooling

Fan CoilOutput Heating

HouseBTUH Loss

Fan CoilOutputCooling

HouseBTUH Gain

Nook 11,808 8,326 4,800 5,233

Kitchen 5,904 2,539 2,400 1,688

Bath 2,952 1,114 1,200 693

Bed #1 5,904 2,667 2,400 1,592

Bed #2 5,904 3,845 2,400 2,165

Dining Rm. 8,856 5,109 3,600 3,802

Foyer 5,904 4,186 2,400 2,166

Family Rm. 8,856 5,859 3,600 4,001

Master Bed 14,760 9,326 6,000 6,046

M.Bath/wic 2,952 2,786 1,200 1,193

Totals 73,800 45,757 30,000 28,579

Not all rooms will check out for cooling as illustrated in Table 17, we allow a 0.1 variance on vent checks per room. The Main concern is the total unit output being higher than house BTUH loss. With the venturi action of the Hi-Velocity System the individual rooms will affect each other and help maintain the desired room temperature.

Difference in Number of Vents Needed for Heating and Cooling

There may be cases when the number of outlets needed for heating is significantly different than the amount needed for cooling. This is usually caused by a large appliance load or an excessive amount of windows. If this happens you will have to use the greater number of outlets to provide both heating and cooling for the room. The vents have dampers and can be adjusted for individual room comfort. In cooling mode the outlets must be in the fully open position or there will be a loss in performance and the efficiency of the system.

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Fig. 31 - House Drawing

This drawing is not to scale.This is an example only and may not reflect an actual heat loss/gain.

••

Glass door6’ x 7’

Dining Room21’ x 11’

Foyer21’ x 10’

Family Room21’ x 16’

Master Bedroom17’ x 22’MB/W.I.C.

10’ x 18’Bedroom #2

14’ x 13’

Bedroom #111’ x 13’

Kitchen13’ x 11’

Nook15’ x 14’

Garage

Wood Door3’ x 7’

2’ x 3’

2’ x 3’

2’ x 3’

2’ x 3’

3’ x 4’

3’ x 4’

4’ x 4’ 4’ x 4’ 4’ x 4’

2’ x 6’

2’ x 6’

4’ x 6’

2’ x 6’

2’ x 6’

4’ x 6’

2’ x 6’

2’ x 6’

4’ x 6’

1’ x 6’

1’ x 6’

Wood Door3’ x 7’

Glass door3’ x 7’

4’ x 6’

Bath11’ x 6’

Design Factors for ESP’s heat calc programAir change/Hour 0.3Altitude above sea level (ft) 1500Outdoor Heating temp (ºF) -15Outdoor Cooling DB temp (ºF) 95Humidity 40%

Glass Double/Coated 0.46Cold floor area R-20 Insulation (6”)Exposed ceiling R-40 insulation (12”)Standard doors 1” solid coreGlass doors High Eff. Patio doorExposed wall R-20 Insulation (6”)Construction New

All ceiling heights are 9’

Fan coil and main plenum will belocated in the crawl space

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System Layout

With the total vents known, the layout of the Hi-Velocity System can now be done. Start with individual vent placements (if you haven’t already read the section on Vents in System Design, please do so before starting). Then place the main plenum so the flex runs will be the shortest length possible. With the plenum placed, the flex runs can be drawn connecting the vent outlet to the main plenum.

Drawing Vent Placement To demonstrate a vent layout, we’ll place 4 vents to

properly condition the Nook (Fig. 32). From table 16 we calculated that the Nook has a Heat loss/gain of 8,326/5,233, which will require 4 vents to satisfy heating and cooling requirements.

Fig. 32 - Placing Vents: Nook

4 Vents distributedevenly throughout

the space.

With this room 3 vents would have satisfied the heating requirements, but would not satisfy the cooling requirements. For the nook we need 4 vents for cooling, so 4 vents must be placed in the nook. The vents do have an adjustable damper and can be adjusted for individual room comfort if too much heating is being supplied. In cooling mode the outlets must be in the fully open position.

The outlets should be located where it is considered to be a “low traffic area”. Typical areas are in the corner of a room, or to the side of a window or door. When the vents are properly located, the home owner can expect to have a nearly draft free home.

Once all the vents have been placed in each room, the main plenum can now be drawn. Fig. 33 shows where all vents have been located in the individual rooms.

Drawing the Plenum

For this layout we have chosen to use a Main Plenum with a 56/44 bullhead tee (Fig. 17) split. On one side 14 vents will used, while 11 will be used on the other. This is allowable as we can use a Bull Head Tee up to a 60/40 split. If the split is greater than 60/40, a Branch Tee (Fig. 16) should be used instead of the Bullhead Tee.

With a 56/44 split we will be able to reach all vents using standard 10’ and 15’ flex runs. If you have to extend the flex runs longer than 10’ (HV and Builders series) reference Table 05 for adjustment factors. Space Savers series minimum length is 5’, and adjustments must be made from table 05 if extending flex runs longer than 5’.

The main plenum we choose to use is 8”, it is not required to use 8” for the whole run. If space or cost is a concern, the main plenum can be reduced down to a smaller size. If reducing the plenum, reference Table 04 for allowable length and maximum number of vents for the size chosen. Never reduce at a bullhead tee, always reduce after the bullhead tee or you can lose approximately 20% of your airflow.

Drawing the Flex Runs

Once the vents and plenum have been drawn in, the two may now be connected with the 2” flexible branch duct. The minimum flex run is 10’ (5’ Space Saver and Builders series) and the maximum is 25’ (15’ space Saver). Builders and Space Saver series are different than the Hi-Velocity System, the minimum and maximum allowable flex lengths can be referenced from Table 17.

Table 17 - Allowable Branch Duct Lengths

Model Min. Length Max. Length

HVBuildersSpace Saver

10’5’5’

25’25’15

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Fig. 33 - House Layout

8” MainPlenum

Fan coil inCrawl space

Branch Ducts to be installed 18” from

elbows, tees, end caps

44% split11 vents

56% split14 vents

Vent installed inthe Kick Space

LegendVentMain Plenum2” Flexible Branch ductVent in Kick Space

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Hi-Velocity Specifications HV-50/51 HV-52 HV-70/71 HV-100/101 HV-140

BTUH @ 190°F E.W.T. 56,200 58,636 79,700 113,400 150,400

BTUH @ 180°F E.W.T. 52,300 54,042 73,800 105,000 138,200

BTUH @ 170°F E.W.T. 48,500 49,455 67,500 95,500 126,000

BTUH @ 160°F E.W.T. 44,400 44,877 62,900 86,300 113,800

BTUH @ 150°F E.W.T. 41,500 40,309 55,000 77,000 101,600

BTUH @ 140°F E.W.T. 37,500 35,753 49,500 68,700 89,500

BTUH @ 130°F E.W.T. 32,700 31,210 44,500 59,300 77,400

BTUH @ 120°F E.W.T. 29,500 26,682 38,000 49,600 65,300

BTUH @ 110°F E.W.T. 23,200 22,171 30,000 37,200 53,300

Electrical Strip Heater 5 - 15 Kw N/A 5 - 18 Kw 5 - 23 Kw N/A

TX Cooling MBH(1) 18 - 24 18 - 24 30 - 36 42 - 60 60

BTUH @ 44°F E.W.T. 24,400 23,700 35,000 51,000 57,900

BTUH @ 42°F E.W.T. 26,000 25,400 37,800 55,000 62,900

C.F.M. @ 1.5” E.S.P. 550 550 750 1100 1250

HP - RPM 1/4 - 1625 1/4 - 1625 1/3 - 1625 1/2 - 1625 3/4 - 1625

AMPS @ 115/1/60 4.5 (High) 4.5 (High) 5.0 7.5 8.5

G.P.M. FLOW RATINGS 5 5 7 10 10

S/A SIZE & MAX. LENGTH 8” - 70’2 x 6” or 1 x 8”

50’8” - 80’ 10” - 100’ 10” - 120’

R/A SIZE NEEDED 12” 12” 12” 14” 16”

MINIMUM OUTLETS(2) 14 8 20 30 40

MAXIMUM OUTLETS 20 19 29 45 50

E.W.T.E.S.P.G.P.M.HPMBHRPMR/AS/ATX

Entering Water TemperatureExternal Static PressureGallons Per MinuteHorse PowerThousand British Thermal Units per HourRevolutions Per MinuteReturn AirSupply AirThermal Expansion

Smaller condensers may be matched to the fan coil when needed (match TXV to condenser size).Minimum number of full outlets per ton of cooling needed.

1.2.

Appendix A – Hi-Velocity Fan Coil Specifications

�0

Appendix B – Product SizingItem Length Width HeightFan coils A B C

HV-50/51 H/BU 32 5⁄16” 14 1⁄2” 18 1⁄4”

HV-52 H/BU 30 1⁄2” 18 1⁄2” 14 1⁄4”

HV-70/71 H/BU 32 5⁄16” 19 1⁄2” 18 1⁄4”

HV-100/101 H/BU 32 5⁄16” 25 1⁄2” 18 1⁄4”

HV-140 H/BU 38 1⁄2” 26 1⁄2” 24 1⁄4”

Refrigerant Modules G E F J K

RCM-50 14 3⁄8” 10 1⁄8” 18 1⁄2” 1⁄2” 7⁄8”

RCM-70 19 3⁄8” 10 1⁄8” 18 1⁄2” 1⁄2” 7⁄8”

RM-100 25 3⁄8” 7” 18 3⁄8” 5⁄8” 7⁄8”

RM-140 25 3⁄8” 7” 18 3⁄8” 5⁄8” 7⁄8”There is no difference between the RM-100 and RM-1400

Water Cooling Modules G E F J K

WCM-50 14 3⁄8” 10 1⁄8” 18 ½” 3⁄4” 3⁄4”

WCM-70 19 3⁄8” 10 1⁄8” 18 ½” 3⁄4” 3⁄4”

WCM-100 25 3⁄8” 7” 18 3⁄8” 3⁄4” 3⁄4”

WCM-140 26 1⁄4” 8” 22 5⁄8” 1” 1”

Heating Coil Add-on B D C H I

HCA-50 13 1⁄2” 5 5⁄8” 16” 1⁄2” 1⁄2”

HCA-70 19” 5 1⁄2” 16” 3⁄4” 3⁄4”

HCA-100 25” 5 1⁄2” 16” 3⁄4” 3⁄4”

HCA-140 25 7⁄8” 6” 22” 1”Heating Coil Add-on does not come as a module, it slides into the Hi-Velocity fan coil

Electrical Strip Heater B D C

HV-650 13 3⁄4” 5 5⁄8” 15 1⁄2”

HV-750 18 3⁄4” 5 5⁄8” 15 1⁄2”

HV-1100 24 3⁄4” 5 5⁄8” 15 1⁄2”Dimensions for the ESH do not include the electrical access panel, add 4” to ESH for Total Length

Refrigerant Pre-Piped Module G F E

RPM - 50 17” 18 1⁄2” 10” 1⁄2” 7⁄8”

RPM - 70 23 1⁄4” 10 1⁄8” 18 1⁄2” 1⁄2” 7⁄8”

RPM - 100 29” 10 1⁄8” 18 1⁄2” 5⁄8” 7⁄8”

www.hi–velocity.com

Phone: (780) 453-2093Fax: (780) 453-1932Toll Free: 1-888-652-2219

Energy Saving Products Ltd., established in 1983, manufactures the Hi-Velocity Systems product line for residential, commercial and multi-family markets. Our facilities house Administration, Sales, Design, Manufacturing, as well as Research & Development complete with an in-house test lab. Energy Saving Products prides itself on Customer Service and provides design services and contractor support.

Comfort from floor to ceiling,

Satisfaction from room to room,

with

It’s not just a dream, it’s reality.

ESP 104.02