1. System
Components
Let’s take a look at the Spacepak System Components.

2. Typical System
The typical system consists of an air handler connected to plenum duct off of which branch take offs are cut in. The 2” branch runs each have a 3’ sound attenuator tube just before the terminator. On the return side we generally use a single central return with a flexible, insulated sound attenuating duct. The return air box as well as the air handler are designed to fit between 16” on center ceiling joist to fit more easily in to attics of existing homes. This evaporator portion of the system is matched with your favorite brand of condenser (check the ARI web site for certified capacities) and piped just like any other unit. There is most importantly condensate piping to a good drain and a safe pan piped separately to a good drain.
copyright Mestek, Inc. 2004

3. Compact Air Handler Small to fit in attic Quiet and durable
Connects to a variety of condensers
All Spacepak D-series air handlers are 14-1/8” tall so that they will fit between 16” O.C. ceiling joists, as are the return air boxes. If the scuttle hole into the attic is too small to fit the unit through they will pass through the return air opening.
Spacepak air handlers are one piece units, so there’s no assembly of the unit required in the attic. You simply build a platform or hang some instruct place the unit on it and start attaching duct.
The air handler itself is very quiet. The cabinet is fully insulated and when all the ducting is sealed you have to put your hand on it to tell if it’s running.
DX systems can connect to pretty much any condensing unit although the minimum allowable SEER by law is now 11.
All DX units have a built-in check valve making them heat pump compatible. DX units are available as either 410A or R-22 compatible (be sure to order the right one for your job)
Pictured here is the WCSP unit which has a 6 row water coil inside it for chilled water systems.

4. E-Series Air Handler
The new E- Series air handler is the result of focus groups with contractors. It features a plastic drain pan with the tappings in front of the coil. The electrical control panel is inside the unit. It has a removable return air rear panel. The TXV and piping has been moved out of the air stream with the connections out the front of the unit, out of the way of the condensate lines.

5. Compact Air Handler Vertical units Closet installations Back halls
Commercial mechanical rooms
This is the vertical unit it is available as DX only 410A or R-22 (there is no WCSP water coil version of this unit)
These can be installed with the add on hot water coil which fits over the return air opening.
This configuration allows you to keep the air handler in conditioned space if you are using a hot water coil eliminating the need for freeze protection.
The high and low voltage control box is inside behind the top panel.

6. Heating Options Hot Water Coils New E-Pak Heat Pumps
Spacepak offers more heating options than any other high velocity system on the market. Hot water coils, heat pumps and electric heat. For heating capacities with hot water coils check the WPAK Hydronic Coil Installation instructions (HWCII-1). For electric heat we offer 3 sizes; 10, 15, and 20 KW units or 34,000, 50, 000 and 68,000 BTU/H. For heat pump unit check the ARI web site for mixed and matched systems.

7. Hydronic Coils
New 4 row coils with 40% increased capacity (60, 90 & 120 MBH)
Supply bottom, return top
Fan delay for heat up
Clip on aquastat
Check valves
In 2004 Spacepak introduced their new 4 row hydronic coils (they used to be 2 row) boosting the capacity by 40%. It is critical to use 1” piping to and from the coil (reducing at the coil) as well as a properly sized circulator to achieve the desired flow rate and BTU performance. Generally hot water is supplied to the bottom fitting and returned from the upper fitting. The supply piping is typically fitted with a strap-on aquastat which delays the blower until the coil gets hot. It’s also important to build proper filling, draining and purging access as well as freeze protect the system.

8. New E-Pak Installs directly into air handler Modulating Heat
Duct sensor in air stream monitors discharge temperature
ETL Listed as a Space Pak Component
Supplemental heat with heat pumps
240V w/24V controls
10kw, 15kw & 20kw sizes
This new unit mounts to an access door and fits into the air handler. The coils can be staged on individually. There is a bult in sensor on the unit to monitor discharge temperature. The unit certified for electrical safety with ETL labs. It can provide all the heat in warmer climates and backup/ defrost supplemental heat for heat pumps. We offer 10,15 and 20 KW units.

9. Heat Pump Space-Saving “Hybrid” systems in colder climates
Use in conjunction with E-Pak
One of the beauties of the heat pump system is that you have heating and cooling all in one system, and the system is in the attic, or basement or crawl space, and outside. You don’t have radiators in the way of your furniture or oil tanks and boiler rooms taking up your basement room. Heat pumps have always been popular in the southern states and warmer climates but now with the cost of fuel rising there are more and more installations in the northern half of the country. The advantage is that it takes up no more room if you are putting in cooling already and it offers the homeowner another heat source from a different fuel. So even in Vermont and Canada in houses that have gas or oil boilers, or wood stoves the heat pump can take the place of those other fuels 90% of the year. Most heat pump systems will also have the E-Pak electric heaters as well for defrost cycles and emergency heat.

10. Chilled Water Coil Model WCSP-”D” Series
For use with chillers & boilers
Multi-zone applications
Alternative to vertical fan-coil units
Spacepak offers a chilled water version of the D-Series unit called the WCSP for water coil Spacepak. These are typically used in very large homes and commercial spaces. It is the same D-series unit except the 6 row DX coil is replaced with a 6 row water coil. These are typically used for heating and cooling in conjunction with a central chiller plant and or a boiler plant. For heating and cooling capacities check the WCSP installation manual on page 7 (WCSPD2-1103). This unit is ideal for multi-zone applications such as office buildings, multi level condo buildings and anywhere that individual control off a central system is required.

11. Plenum Take Offs
Spacepak offers two different types of plenum take-offs: one for metal round and one for 1” square ductboard. The come in packs of 2 or 5 to match the installation kits.

12. Installation Kits

13. Sound Attenuator 3 foot standard section Pre-assembled connectors
Reduces velocity noise
End of every run
At the end of each run just upstream of the outlet is a 3’ sound attenuation tube. These tubes are different from the supply tubing in that they have a fabric lining which keeps the system quiet.

14. Standard Outlet Flex Seals to Ceiling
The outlets come with spring clips that catch the backside of the sheetrock and hold the faceplate tight to the ceiling. You always want to install the faceplates so that the screws align with the direction of the tubing run. This will insure that the faceplate stays tight to the ceiling.

15. Square Duct Board
Spacepak offers 8 x 8” square ductboard plenum and accessories. It’s 1” thick R- 4.3 and comes in a box of 6 4’ lengths. The accessories also come in boxes of 4. (except the end caps that come in a box of 10) This stuff is very easy to work with you can cut it on site very easily, the Spacepak quick connect system works very well with it, it’s light, easy to support… The important thing is to use the right tape when sealing the joints. The tape must be labeled UL- 181 and the glue on the tape must be rated for the most extreme temperature the space will see where it is installed.

16. Return Duct
It is easiest to attach the return duct to the return air box before it is installed. To do this squish the return duct into an oval shape at one end. Extend the white inner duct beyond the insulation and mylar jacket. Get 2 or three ribs of the inner duct over the oval flange of the return air box. Use self taping sheet metal screws and washers (a bottle cap from your favorite beverage work the best) and capture one of the ribs while attaching it to the collar. Then tape the joint. Pull the insulation and mylar back up and attach with the band clamp and tape. Then set the box into the return hole.

17. Central Return Air Most systems require only a single return
Recommended to use supplied return
Return opening fits air handler
Location of return dictates air handler location
1pc., flexible, insulated, sound attenuating, return duct
Return Duct
Model
24”
ESP-4860
19”
ESP-3642
15”
ESP-2430
Most Spacepak systems use only one central return because we are not changing the air in each room like a conventional system. Ideally we want to place the return at the top of the stairs in the hallway (for cooling systems) where the warmest air in the house collects. We recommend using Spacepak parts because they have been tested with the unit. The pressure drop of the filter and the return duct, the free area of the grill have been tested and proven to work properly. Can you do something else for the return? Yes, If you know the rules. Another advantage to using the Spaceapk parts is that the unit will fit through the hole you cut for the grill and also the return box and grill fit between 16”O.C. joists. Typically the air handler is mounted with in 6’ of the return air opening. The Spacepak return duct is a one piece, flexible, insulated, sound attenuating duct that is quickly and easily installed(or removed if need be). For heating it is better in the downstairs hallway or in the coldest central room in the down stairs. If the system is doing both heating and cooling it would be ideal to have both and be able to damper them depending on the season.

18. New R-8” Supply Tubing
Meets new codes where R8 is required in uninsulated space
6-1/2” O.D. uncompressed
Here is the R-8 tube and note that the OD without squishing down the insulation.

19. Pure Pak Electronic Air Cleaner
97% capture efficiency of contaminates down to .3 microns
No ozone production
24 V, 1-1/2 VA
High efficiency filtering is a key component to any HVAC system and home owners are becoming more aware of indoor air quality. You may even have an existing system in a house where one of the occupants is allergic to the cat. Now you can solve that problem with a Spacepak tested and approved electrostatic filter. Inside the blue media is a charged carbon core that absorbs orders and creates a polarizing field that collects dust particles like a magnet. This is a 24 volt system that connects right to the low voltage terminal block of the air handler. It only turns on when the fan turns on.

20. PurePak Efficiency 97% capture at .3 microns!
This shows the effectiveness of the PurePak filter as compared to 4-6” pleated filters. A lot of you may have another filter that you’ve been using and are comfortable with and your question is; will it work? The answer is yes if it meets the pressure drop requirements of the Spacepak return system. We know the PurePak filter does meet the requirements.
97% capture at .3 microns!

21. Direct Mount Filter Box
For ductless returns
Fits in tight spaces
May be louder
Spacepak offers a direct-mount filter box that attaches directly to the back of the unit. This is used where the space above a drop ceiling is being used as the return plenum in commercial spaces or if the unit is mounted in a hall closet with a louvered door. This is a good option if you are using the hot water coil and are afraid of it freezing in the attic in the winter, that way only the ductwork is in unconditioned space. Of course there are no sound attenuating qualities to this option but in most cases it is not a problem.