CBK45UHPT Multi Position Air Handlers
“
Product Information
Specifications
- Model: MULTI-POSITION AIR HANDLERS 508437-01
- Date: 3/25/2025
- Altitude of Application: Maximum 3200m above sea level
- Refrigerant Type: A2L
Product Usage Instructions
Installation
1. Installation and service must be performed by a licensed
professional HVAC installer or equivalent.
2. Follow all instructions provided in the installation manual
for proper setup.
Safety Guidelines
1. Only competent persons should carry out procedures affecting
safety.
2. Do not use the appliance if you have reduced physical,
sensory, or mental capabilities unless supervised.
3. Children should be supervised to prevent them from playing
with the appliance.
Maintenance
1. Servicing should only be performed as recommended by the
manufacturer.
2. Service personnel must be properly trained with A2L
refrigerants.
Air Quality
1. Ensure ducts connected to the appliance do not contain
potential ignition sources.
2. Use only auxiliary devices approved by the manufacturer for
appliances using A2L refrigerants.
Altitude Adjustment
1. Consult the Altitude Adjustment Factor table for altitude
adjustments if necessary.
Frequently Asked Questions (FAQ)
Q: Can anyone install or service the unit?
A: No, installation and service must be done by a licensed
professional HVAC installer or equivalent.
Q: What should I do if I detect a leak?
A: In case of a leak, the unit must be powered off except for
service and a licensed professional should be contacted for
repair.
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©2025 Lennox Industries Inc. Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE
WARNING
Every working procedure that affects safety means shall only be carried out by competent persons. This appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure they do not play with the appliance.
CAUTION
Leak Detection System installed. Unit must be powered except for service.
WARNING
Maximum Altitude of application is 3200m above sea level.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional HVAC installer or equivalent, service agency, or the gas supplier.
CAUTION
Servicing shall be performed only as recommended by the manufacturer.
INSTALLATION INSTRUCTIONS
Merit® Series
CBK45UHPT Air Handler Units R454B
MULTI-POSITION AIR HANDLERS 508437-01 3/25/2025
Table of Contents
General Information ……………………………………………….2 Wiring Diagrams ……………………………………………………3 Air Flow Cooling Blower Speed …………………………….4 Requirements ……………………………………………………….6 Unit Dimensions Upflow ………………………………………7 Unit Dimensions Horizontal ………………………………….8 Installation Clearances …………………………………………..9 Installation ……………………………………………………………9 Sensor / Bracket Installation…………………………………..13 Condensate Drain…………………………………………………15 Duct System and Filters ………………………………………16 Brazing Refrigerant Lines ……………………………………..17 Sealing the Unit …………………………………………………..20 Electrical Connections ………………………………………….20 Check-out Procedures ………………………………………….21 Operation …………………………………………………………..22 Homeowner Maintenance ……………………………………..22 Repairing or Replacing Cabinet Insulation ………………23 Professional Maintenance …………………………………….23 Sensor Maintenance …………………………………………….24 Modes of Operation ………………………………………………24 Start Up Test Procedure ………………………………………..26 Decommissioning ………………………………………………..27
NOTE This unit is a PARTIAL UNIT AIR CONDITIONER, complying with PARTIAL UNIT requirements of this Standard, and must only be connected to other units that have been confirmed as complying to corresponding PARTIAL UNIT requirements of this Standard, UL 60335-2-40/CSA C22.2 No. 60335-2-40, or UL 1995/CSA C22.2 No 236. Partial units shall only be connected to an appliance suitable for the same refrigerant.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs and HFCs) as of July 1, 1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance.
WARNING
Ducts connected to an appliance shall not contain a potential ignition source
Page 1
WARNING
· Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer.
· The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance, or an operating electric heater).
· Do not pierce or burn.
· Be aware that refrigerants may not contain an odor.
WARNING
For appliances using A2L refrigerants connected via an air duct system to one or more rooms, only auxiliary devices approved by the appliance manufacturer or declared suitable with the refrigerant shall be installed in connecting ductwork.
WARNING
Ducts connected to an appliance shall not contain a potential ignition source
WARNING
Auxiliary devices which may be a potential ignition source shall not be installed in the duct work. Examples of such potential ignition sources are hot surfaces with a temperature exceeding 700°C and electric switching devices.
WARNING
For duct connected appliances, false ceilings or drop ceilings may be used as a return air plenum if a REFRIGERANT DETECTION SYSTEM is provided in the appliance and any external connections are also provided with a sensor immediately below the return air plenum duct joint.
CAUTION
Any service personnel installing, decommissioning, or performing maintenance on the unit must be properly trained with A2L refrigerants
WARNING
If this appliance is conditioning a space with an area smaller than TAmin, then that space must be without continuously operating open flames (e.g. an operating gas appliance) or other potential ignition sources (e.g. an operating electric heater or similar hot surface). A flame-producing device may be installed in the same space if the device is provided with an effective flame arrest system.
TAmin Table
Charge (lb)
10.0 15.0 20.0 25.0 30.0
Charge (kg)
4.5 6.8 9.1 11.3 13.6
Minimum Conditioned Area (ft2)
149.9
224.9
299.9
374.8
449.8
Minimum Conditioned Area (m2)
13.9
20.9
27.9
34.8
41.8
NOTE Multiply values in TAmin table by the Altitude Adjustment Factors to correct TAmin based on installed altitude.
Altitude Adjustment Factor
Altitude (m)
0
200
400
600
800
1000
1200
1400
1600
Altitude (ft)
0
660
1310
1970
2620
3280
3940
4590
5250
Adj. Factor
1
1
1
1
1.02
1.05
1.04
1.1
1.12
Altitude (m)
1600
1800
2000
2200
2400
2600
2800
3000
3200
Altitude (ft)
5250
5910
6560
7220
7870
8530
9190
9840
10500
Adj. Factor
1.12
1.15
1.18
1.21
1.25
1.28
1.32
1.36
1.4
General Information
The CBK45UHPT series air handler with all-aluminum coil is designed for indoor installation only. As shipped, the unit is ready for installation in either upflow, horizontal left-hand or right-hand air discharge applications. Electric heat, downflow air discharge kits, air filters and other accessories are available and listed in the CBK45UHPT Product Specification bulletin for ordering.
This instruction is intended as a general guide and does not supersede local or national codes in any way. Consult authorities having jurisdiction before installation.
Shipping and Packing List
Package 1 of 1 contains: 1 Assembled air handler unit factory-equipped for upflow
or horizontal air discharge application (includes upflow and horizontal drain pans and preinstalled air filter). Check the air handler for shipping damage; if found, immediately contact the last carrier. Check the unit rating plate to confirm that delivered unit matches order.
IMPORTANT: Special procedures are required for cleaning the all-aluminum coil in this unit. See page 23 in this instruction for information.
Page 2
Wiring Diagrams
14 BLK L1 14 YEL L2 24V
PART NO. 538437-01
WIRING DIAGRAM – ELECTRIC HEAT
YEL BLK
RED BLK
BLK YEL
YEL BLK
BLK BLK
YEL YEL
SEQ
RED
BLK WHT BLU
WHT
6 54 3 21
SEQ BLU
BLK YEL
SEQ
BLU BLK
BLK YEL
BLK BLK SEQ YEL
BLU
CB
ON OFF
ON OFF
20KW
YEL
HTR 4 SEC L
HTR 3 SEC L
HTR 2 SEC L
HTR 1 SEC L
L2
L1
L2
L1 HTR 4 PRI LS
HTR 3 PRI LS
HTR 2 PRI LS
HTR 1 PRI LS
YEL RED BLK
BLK YEL YEL
RED BLK
WHT BLU
6 54 3 21
BLK
RED WHT BLU
6 54 3 21
SEQ WHT
SEQ WHT
SEQ BLU
BLK
BLK
YEL
SEQ
BLU CB
BLK BLK
SEQ
YEL
YEL
BLU
HTR2 SEC L
ON OFF
ON OFF
BLK BLK
YEL
YEL
BLK
YEL
HTR3 SEC L
L2
L1
L2
HTR3
L1
PRI LS
7.5KW & 10KW
HTR1 SEC L
YEL BLK
RED BLK BLK YEL YEL
ON OFF
CB OR TB L1 L2
HTR2 PRI LS
HTR1 PRI LS
12.5KW & 15KW
HTR2 SEC L
HTR2 PRI LS
HTR1 SEC L
HTR2 PRI LS
HEATERS USED
4 KW & 5 KW = HTR1. 7.5 & 10KW = HTR1, HTR2 12.5 KW & 15KW = HTR1, HTR2 & HTR3 20 KW = HTR1, HTR2,HTR3 & HTR4
TB = TERMINAL BLOCK CB = CIRCUIT BREAKER SEQ = SEQUENCER GND = GROUND LUG PRI LS= LIMIT SWITCH SEC L= LIMIT SWITCH HTR = HEATER ELEMENT
RED WHT
BLU 6 54 3 21
SEQ
BLK YEL
HTR 1 CB OR TB
4KW & 5KW
YEL BLK
RED BLK
YEL
HTR 1
12
3
4
56
COM 208V 240V
TRANSFORMER
24
18 RED
18 BLU C
F1 18 BLK 18 WHT GND 18 BLU
18 GRN
3
5
18 RED
1
2
TIME DELAY
R O Y2 G Y1 W1 C W2 DS
14 RED 18 BLU 18 GRN
14 BLK 18 BLU
BLOWER
RELAY
3
1
6
5
#
14 BLUE (MED)
4
2 14 RED(LO)
14 BLK(HI)
14 YEL(COM)
# FACTORY SPEED SET TO MEDIUM (BLUE)
GND
BLUE 4
BRN/WHT
RED
3 BLK MTR
2
YEL
BRN CAP
1
POWER (FACTORY WIRED) POWER (FIELD WIRED) CONTROL (FACTORY WIRED) CONTROL (FIELD WIRED)
CONTROL CIRCUIT WIRING TO BE 24 VOLT, N.E.C. CLASS 2
PLUG PIN LOCATION
THREE POLE SEQUENCER
TIMING – SEC
ON
OFF
1-20
40-110
20-60 1-30
20-60 1-30
THREE POLE SEQUENCER TIMING – SEC
ON 30-90 30-90
OFF 1-30 1-30
**TD = TIME DELAY (OPT.) TR = TRANSFORMER BR = BLOWER RELAY MTR = BLOWER MOTOR CAP = MOTOR CAPACITOR GND = GROUND CONNECTION F1 = FUSE 3 AMP, BLADE TYPE, 32V
14 BLK 14 YEL(240V)
14 WHT(120V)
14 GRN
WIRING DIAGRAM: NO HEAT
WIRE NUTS
BY OTHERS
L1
L2 OR NEUT.
15 AMP
SUPPLY VOLTAGE
1 2
6-PIN PLUG
GND
ELECTRIC HEAT
PSC LABEL WIRING DIAGRAM
Supersedes
C 2011
Litho U.S.A.
FIGURE 1. Typical Wiring Diagram CBK45UHPT Air Handler with Electric Heat PSC
Page 3
THERMOSTAT
AIR HANDLER RDS CONTROL BOARD
R
G
SEE
BU
NOTE
Y
THERMOSTAT
AIR HANDLER RDS CONTROL BOARD
R
G
SEE
BU
NOTE
W
HEAT-ONLY APPLICATION
AIR CONDITIONER
UNIT
COOLING-ONLY APPLICATION
THERMOSTAT
AIR HANDLER RDS CONTROL BOARD
R
AIR HANDLER
THERMOSTAT
RDS CONTROL BOARD
G
R
G W BK
CONNECT COMMON WIRE ONLY IF REQUIRED
(REFER TO THE APPROPRIATE THERMOSTAT INSTALLATION
INSTRUCTIONS)
BU BK
W
SEE NOTE
Y BU
HEAT PUMP UNIT
AIR CONDITIONER UNIT
HEAT PUMP APPLICATION WITH ELECTRIC HEAT
COOLING APPLICATION WITH
ELECTRIC HEAT
NOTE – Connect common wire only if required (Refer to the appropriate thermostat installation instructions).
FIGURE 2. Low Voltage Connections (3-Speed PSC Motor) Field Wiring
Air Flow Cooling Blower Speed
The cooling blower speed is factory configured to provide correct air flow for an outdoor unit that matches the cooling capacity rating of the air handler. If the outdoor unit is smaller than the maximum cooling capacity rating for the air handler, the cooling blower speed may need to be changed. Refer to blower performance chart, TABLE 1 on page 5.
IMPORTANT
Minimum Air Flow when RDS initiates mitigation is factory set at 350 CFM Per Ton.
WARNING
Electric shock hazard! – Disconnect all power supplies before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
CHANGE BLOWER SPEED
1 – Disconnect all power supplies.
2 – Remove the air handler access panel.
3 – Locate pin number 2 on the blower relay. Two black wires are connected to this terminal pin. One connects to pin number 5 on the blower relay, one connects to an in-line splice connecting to a blue wire.
4 – Select the required blower motor speed. Connect red-LO or black-HI and plug it into the 4-pin blower relay harness connector.
NOTE – Reuse the factory-installed wire nut on the unused wires.
5 – Replace all panels.
6 – Reconnect power.
Page 4
BLOWER RELAY
NOTE – Refer to wiring diagram located on the unit ance (table 1).
All air data measured external to unit with 1 inch non-pleated air filter in place. All factory settings are medium speed.
All data given while air handler is operating with a dry DX coil.
All downflow applications run on high speed when utilizing electric heat.
5 BLOWER RELAY HARNESS
BLUE (MED)
2
4-PIN BLOWER CONNECTOR
FIGURE 3. Changing Blower Speed
PLASTIC CAPS RED (L0) BLACK (HI)
YELLOW (COM)
TABLE 1. CBK45UHPT Blower Performance (3-Speed PSC) 240V (CFM @ ESP. in. W. C.)
Air Handler Model -018 -024 -030 -036 -042
Blower Speed LOW MED HIGH LOW MED HIGH LOW
MED HIGH LOW MED HIGH LOW MED HIGH
.10″ WC
538 688 919 677 1011 1106 871
1078 1311 1020 1276 1559 1,300 1,527 1,816
.20″ WC
525 670 881 673 979 1045 870
1057 1261 972 1240 1521 1,273 1,493 1,756
.30″ WC
503 639 855 657 942 999 853
1024 1214 956 1191 1446 1,250 1,452 1,693
.40″ WC
471 603 788 629 803 917 812
987 1154 909 1148 1395 1,211 1,390 1,605
B· loCwoeorlinPgersfopremedasncseho(CulFdMnovtsb. eESrePduinccehdesbeHlo20w) factory setting. · All units with electric heat are approved at 0.5″ at maximum and medium blower speed. · All downflow applications run on high speed when utilizing electric heat.
.50″ WC
418 548 710 592 742 857 769
936 1086 806 1086 1327 1,155 1,345 1,528
IMPORTANT
This unit is approved for installation clearance to combustible material as stated on the unit rating plate. Accessibility and service clearances must take precedence over combustible material clearances.
The air handler must be installed so that free access is allowed to the coil/filter compartment and blower/control compartment.
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment and wear gloves and protective clothing.
WARNING
To prevent serious injury or death:
1. Lock-out/tag-out before performing maintenance.
2. If system power is required (e.g., smoke detector maintenance), disable power to blower, remove fan belt where applicable, and ensure all controllers and thermostats are set to the “OFF” position before performing maintenance.
3. Always keep hands, hair, clothing, jewelry, tools, etc. away from moving parts.
WARNING
Excessive Weight Hazard – Use two or more people when moving and installing the unit. Failure to do so can result in back or other type of injury.
Page 5
Requirements
IMPORTANT
CBK45UHPT units include a factory-installed check/ expansion valve which will provide optimal refrigerant control and system performance with outdoor units of varying capacities. These units must be installed as a part of a matched system as outlined in the CBK45UHPT Product Specification bulletin.
These instructions are intended as a general guide and do not supersede local or national codes in any way. Consult authorities having jurisdiction before installation.
Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation. Read this instruction manual, as well as the instructions supplied in separate equipment, before starting the installation.
In addition to conforming to manufacturer’s installation instructions and local municipal building codes, installation of Lennox air handler units (with or without optional electric heat), MUST conform with National Fire Protection Association (NFPA) standards: “Standard for Installation of Air Conditioning and Ventilation Systems” (NFPA No. 90A) and “Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems” (NFPA No. 90B).
All models are designed for indoor installation only. The installation of the air handler, field wiring, duct system, etc. must conform to the requirements of the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, and local ordinances (including plumbing or waste water codes).
Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual.
Install the conditioned air plenum, ducts and air filters (provided) in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition).
The air handler is shipped from the factory completely assembled. The unit is provided with flanges for the connection of the duct system.
Do not remove the cabinet knockouts until it has been determined which knockouts will need to be removed for the installation.
Select the air discharge position which best suits the site conditions. Consider required clearances, space, routing requirements for refrigerant line, condensate disposal, filters, duct system, wiring, and accessibility for service. Refer to the rating plate on the air handler for specific information.
WARNING
Danger of explosion. Keep flammable materials and vapors, such as gasoline, away from air handler. Place air handler so that heating elements are at least 18 inches (46 cm) above the floor for a garage installation. Failure to follow these instructions can result in death, explosion, or fire.
IMPORTANT INFORMATION FOR INSTALLER
This unit has a delay relay that delays the supply blower “ON” for 1 second and keeps the blower “ON” for 45 seconds on all fan and cooling demands. For more details, refer to page 17 for unit sequence of operation.
3
4
12
100% CFM
100% CFM
OFF 1
SECOND DELAY
COOLING DEMAND
45 SECS
Page 6
Unit Dimensions Upflow
1 (25)
1 (25)
SUPPLY AIR OPENING
14-1/2 (368)
C
VOLTAGE INLETS (Top and Left Side)
3/4 (19)
TOP VIEW B
CIRCUIT BREAKER
COVER
1 (25)
VO LTAGE INLETS (Top and Right Side)
DETAIL OF PIPING PLATE
3/4 (19) SUCTION
LINE LIQUID
LINE
2-3/8 (60)
4-3/8 (111) 2-3/4
(70)
1-3/4 (44)
4-3/4 (121)
CONDENSATE DRAINS (2) (Horizontal)
CONDENSATE DRAINS (2) (Upflow and Downflow)
3-1/2 (89)
VOLTAG E INLETS
(Top and Right Side)
VO LTAG E INLETS
(Either Side)
22 (559)
AIR FLOW
A
1-1/8 (29)
PIPING PLATE
D
OPENING
FRONT VIEW
CONDENSATE DRAIN PIPING PLATE (3) (2-1/4 x 3-3/4)
FILTER ACCESS
SUCTION LINE
LIQUID LINE
1-1/8
1/2
(29)
(13)
20-3/8 (518)
OPENING
SIDE VIEW
1-1/8 (29)
Dimensions
A B C D
018
in.
mm
43-1/2 1105
18-1/2 470
16-1/2 419
16-1/4 413
024
in.
mm
45-1/2 1156
18-1/2 470
16-1/2 419
16-1/4 413
030
in.
mm
47
1194
18-1/2 470
16-1/2 419
16-1/4 413
036, 042
in.
mm
53-5/8 1362
21-1/2 546
19-1/2 495
19-1/4 489
Page 7
Unit Dimensions Horizontal
DETAIL OF PIPING PLATE
CONDENSATE
CONDENSATE DRAINS (2)
DRAINS (2)
4-3/4 (121)
(Horizontal)
(Upflow and Downflow)
3-1/2 (89)
3/4 (19)
SUCTION LINE LIQUID
LINE 2-3/8 (60)
4-3/8 (111)
1-3/4 (44)
2-3/4 (70)
22 (559)
VOLTAGE INLETS (Top and Right Side)
1-1/8 (29)
20-3/8 (518)
OPENING
VOLTAGE INLETS (Either Side)
1/2 (13)
SUCTION LIQUID
TOP VIEW
LINE
LINE
VOLT AGE
1 (25)
INLETS (Top and Right Side)
CONDENSATE DRAIN PIPING PLATE (3) (2-1/4 x 3-3/4) FILTER ACCESS
1-1/8 (29)
1 (25)
C SUPPLY AIR
OPENING
14-1/2 (368)
B
CIRCUIT
BREAKER
COVER
AIR FLOW
PIPING PLATE
1 (25)
VOLTAG E INLETS
3/4 (19)
(Top and Left Side)
END VIEW
A FRONT VIEW
D OPENING
1-1/8 (29)
Dimensions
A B C D
018
in.
mm
43-1/2 1105
18-1/2 470
16-1/2 419
16-1/4 413
024
in.
mm
45-1/2 1156
18-1/2 470
16-1/2 419
16-1/4 413
030
in.
mm
47
1194
18-1/2 470
16-1/2 419
16-1/4 413
036, 042
in.
mm
53-5/8 1362
21-1/2 546
19-1/2 495
19-1/4 489
Page 8
NOTES
During cooling operation, excessive sweating may occur if the air handler is installed in a warm and humid space.
If installed in an unconditioned space, sealant should be applied around the electrical wires, refrigerant tubing, and condensate lines where they enter the cabinet.
Electrical wires should be sealed on the inside where they exit the conduit opening. Sealant is required to prevent air leakage into, and condensate from forming inside of, the air handler, the control box, and on the electrical controls.
This unit is approved for installation clearance to combustible material as stated on the unit rating plate. Accessibility and service clearances must take precedence over combustible material clearances.
The air handler must be installed so that free access is allowed to the coil/filter compartment and blower/control compartment.
Installation Clearances
NON-DUCTED RETURN CLOSET INSTALLATION
The air handler can be installed in a closet with a false bottom to form a return air plenum. It may also be installed with a return air plenum under the air handler.
Louvers or return air grilles are field-supplied. Local codes may limit application of systems without a ducted return to single-story buildings.
When a CBK45UHPT unit is installed in a closet with a louvered return opening, the minimum open area for the louvers will be: · 320 square inches for -018 and -024 models;
· 360 square inches for -030 and -036 models;
· 450 square inches for -042 model
If the free area is not known, assume a 25% free area for wood or a 75% free area for metal louvers or grilles. Using the louver dimensions and the 25% or 75% assumption, determine if the open area meets the minimum open area listed above.
If a return air plenum is used, the return air grille should be immediately in front of the opening in the plenum to allow for the free flow of return air. When not installed in front of the opening, there must be adequate clearance around the air handler to allow for the free flow of return air.
Installation
Every working procedure that affects safety means shall only be carried out by competent persons. This appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Examples of such working procedures are breaking into the refrigerating circuit, opening of sealed components, and opening of ventilated enclosures.
· Work shall be undertaken under a controlled procedure so as to minimize the risk of a flammable gas or vapor being present while the work is being performed.
· The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially toxic or flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with all applicable refrigerants, i. e. non-sparking, adequately sealed or intrinsically safe.
· If any hot work is to be conducted on the refrigerating equipment or any associated parts, the appropriate fire extinguishing equipment shall be available to hand. Have a dry powder or CO2 fire extinguisher adjacent to the charging area.
· No person carrying out work in relation to a refrigerating system which involves exposing any pipe work shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing and disposal, during which refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “No Smoking” signs shall be displayed.
· Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. Ventilation should disperse any released refrigerant. When possible, expel refrigerant directly into the atmosphere.
· Pipe-work including piping material, pipe routing, and installation shall include protection from physical damage in operation and service, and be in compliance with national and local codes and standards
· All field joints shall be accessible for inspection prior to being covered or enclosed
· Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt, consult the manufacturer’s technical department for assistance. The following checks shall be applied to installations using FLAMMABLE REFRIGERANTS as applicable:
1. The actual refrigerant charge is in accordance with the room size within which the refrigerant containing parts are installed.
2. The ventilation machinery and outlets are operating adequately and are not obstructed.
3. If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant.
4. Markings on the equipment should be visible and legible. Markings and signs that are illegible shall be corrected.
Page 9
5. Refrigerating pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.
· For systems containing refrigerant, all repair and maintenance to electrical components shall include initial safety checks and component inspection procedures such as that capacitors are discharged in a safe manner to avoid possibility of sparking, that no live electrical components and wiring are exposed while charging, recovering, or purging the system, and that there is continuity of earth bonding. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used that is reported to the owner of the equipment, so all parties are advised.
NOTE Sealed electrical components shall be replaced,
not repaired.
NOTE Intrinsically safe components must be replaced,
not repaired. NOTE All maintenance staff and others working in the local area shall be instructed on the nature of work being carried out with work in confined spaces being avoided.
· Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used. The following leak detection methods are deemed acceptable for all refrigerant systems. Electronic leak detectors may be used to detect refrigerant leaks but, in the case of flammable refrigerants, the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed, and that 12.5 % refrigerant is confirmed. Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. If a leak is suspected, all naked flames shall be removed/ extinguished. If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak.
· When breaking into the refrigerant circuit to make repairs or for any other purpose conventional procedures shall be used. However, for flammable refrigerants it is important that best practice be followed and, since flammability is a consideration, procedures such as safely remove refrigerant following local and
national regulations, purging the circuit with inert gas, evacuating (optional for A2L), purging with inert gas (optional for A2L), or opening the circuit by cutting or brazing be adhered to. The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen to render the appliance safe for flammable refrigerants. This process might need to be repeated several times. Compressed air or oxygen shall not be used for purging refrigerant systems. For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the system with oxygen-free nitrogen and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum (optional for A2L). This process shall be repeated until no refrigerant is within the system (optional for A2L). When the final oxygen-free nitrogen charge is used, the system shall be vented down to atmospheric pressure to be able to perform the required work. Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and working area is well ventilated.
Each unit consists of a blower assembly, refrigerant coil, and controls in an insulated galvanized steel factory-finished enclosure. Knockouts are provided for electrical wiring entrance.
For ease in installation, it is best to make any necessary coil configuration changes before setting air handler in place.
IMPORTANT
Excessive condensation may occur if the unit is installed in a warm, humid place. When the unit is installed in an unconditioned space, apply sealant around electrical wires, refrigerant piping and condensate lines at the point where they enter the cabinet.
Apply sealant on the inside of the cabinet at the point where the electrical wires exit through the conduit opening. This will also keep warm and moist unconditioned air out of the air handler cabinet where it will form condensate on the cooler control box and electrical controls.
REFRIGERANT METERING DEVICE
CBK45UHPT units are equipped with a factory-installed check/ expansion valve.
UPFLOW APPLICATION
1 – The air handler must be supported on the bottom only and set on solid floor or field-supplied support frame. Securely attach the air handler to the floor or support frame.
2 – If installing a unit in an upflow application, remove the horizontal drain pan. IMPORTANT – The horizontal drain pan is not required in upflow air discharge installations; its removal provides
the best efficiency and air flow.
Page 10
3 – Place the unit in the desired location and slope unit. Connect return and supply air plenums as required using sheet metal screws.
4 – Install units that have no return air plenum on a stand that is at least 14″ from the floor. This will allow proper air return.
UP-FLOW / DOWN-FLOW DRAIN PAN
HORIZONTAL DRAIN PAN (MUST BE REMOVED)
FIGURE 4. Upflow Configuration HORIZONTAL APPLICATIONS
IMPORTANT
When removing the coil, there is a possibility of danger of equipment damage and personal injury. Be careful when removing the coil assembly from a unit installed in right- or left-hand applications. The coil may tip into the drain pan once it is clear of the cabinet. Support the coil when removing it..
NOTE – When the unit is installed in horizontal applications, a secondary drain pan is recommended. Refer to local codes.
NOTE – This unit may be installed in left-hand or righthand air discharge horizontal applications. Adequate support must be provided to ensure cabinet integrity. Ensure that there is adequate room to remove service and access panels if installing in the horizontal position.
RIGHT-HAND DISCHARGE
1 – Determine which plugs are required for drain line connections.
2 – With access door removed, remove drain line plugs to install drain lines.
3 – Set unit so that it is sloped toward the upflow drain pan end of the unit and level from front to back of unit (see FIGURE 14).
4 – The horizontal configuration is shown in FIGURE 5.
Drains
AIR FLOW
RIGHT-HAND DRAINS
PLUGS
FIGURE 5. Right-Hand Discharge Configuration
5 – If the unit is suspended, the entire length of the cabinet must be supported. If you use a chain or strap, use a piece of angle iron or sheet metal attached to the unit (either above or below) to support the length of the cabinet. Use securing screws no longer than 1/2 inch to avoid damaging the coil or filter. See FIGURE 6. Use sheet metal screws to connect the return and supply air plenums as required.
ANGLE IRON OR SHEET METAL MAXIMUM 1/2″
LONG SCREW
E ANCE 4 IN. (102 MM)
AIR FLOW
FRONT VIEW
END VIEW
FIGURE 6. Suspending Horizontal Unit
LEFT-HAND AIR DISCHARGE
For horizontal left-hand air discharge, the following field modifications are required.
1 – Remove access panels and the corrugated padding between the blower and coil assembly. Discard the corrugated padding.
2 – Pull the coil assembly from unit. Pull off the horizontal drain pan.
3 – Remove the drain plugs from back drain holes on horizontal drain pan and reinstall them on front holes.
IMPORTANT
After removal of drain pan plug(s), check drain hole(s) to verify that drain opening is fully open and free of any debris. Also check to make sure that no debris has fallen into the drain pan during installation that may plug up the drain opening.
4 – Rotate drain pan 180º front-to-back and install it on the opposite side of the coil.
5 – Remove screws from top cap.
6 – Remove plastic plug from left hole on coil front end seal and reinstall plug in back hole.
Page 11
CABINET SUPPORT
TOP CAP ROTATED TO CORRECT POSITION
TOP CAP SCREWS
DRAIN PAN REINSTALLED
HERE
90º BEND
DRAIN PAN SHIPPING LOCATION
——– DRAIN PLUGS ——–
REINSTALLED HERE
REMOVED FROM HERE
COIL SHOWN IN UPLOAD POSITION FOR EASY CONVERSION
TOP CAP
ALIGN HOLES WITH HOLES IN COIL END PLATE. STARTING WITH THE ROUND HOLES ON THIS END.
90º BEND
BACK COIL END SEAL
FIGURE 7. Field Modification for Left-Hand Discharge
7 – Rotate top cap 180º front-to-back and align with unused screw holes. Holes must align with front and back coil end plates. The top cap has a 45º bend on one side and a 90º bend on the other. The 90º bend must be on the same side as the horizontal drain pan as illustrated in FIGURE 7.
NOTE Be very careful when reinstalling the screws into the coil end plate engaging holes. Misaligned screws may damage the coil.
8 – From the upflow position, flip cabinet 90º to the left and set into place. Replace blower assembly. Secure coil in place by bending down the tab on the cabinet support rail as illustrated.
NOTE For horizontal applications in high humidity areas, remove the downflow rail closest to the drain pan. To remove rail, remove screw from rail at back of unit and at cabinet support rail. Remove downflow rail then replace screws. Also, seal around the exiting drain pipe, liquid and suction lines to prevent infiltration of humid air.
9 – Knock out drain seal plate from access door. Secure plate to cabinet front flange with screw provided.
10 – Flip access door and replace it on the unit.
11 – Set unit so that it is sloped 1/4 toward the drain pan end of the unit. Connect return and supply air plenums as required using sheet metal screws.
12 – If suspending the unit, it must be supported along the entire length of the cabinet. If using chain or strap, use a piece of angle iron or sheet metal attached to the unit (either above or below) so that the full length of the cabinet is supported. Use securing screws no longer than 1/2 to avoid damage to coil or filter, as illustrated in FIGURE 6. Connect return and supply air plenums as required using sheet metal screws.
DOWNFLOW APPLICATION NOTE If downflow application is required, separately order kit number Y9658 (-018 through -030) or Y9659 (-036 through -042) and install per kit’s instructions. Also use metal or class I supply and return air plenums. Use the installation instruction provided with the downflow kit.
IMPORTANT
If electric heat section with circuit breakers (ECB45) is installed in a CBK45UHPT unit in a downflow application, the circuit breakers must be rotated 180° to the UP position. See ECB45 installation instructions for more details.
Page 12
Sensor / Bracket Installation
Vertical Configuration Leak detection sensor and bracket are factory-installed for vertical installation. No sensor relocation is required if installing in vertical configuration.
NOTE The leak detection sensor needs to be relocated for horizontal right, horizontal left, and downflow configurations.
Horizontal Right Configuration 1 – Remove sensor bracket assembly from vertical position (shown in FIGURE 8). Do not remove sensor from bracket, and do not disconnect or reroute sensor wire from the control panel area.
FIGURE 10
FIGURE 8
2 – Follow instructions for right-hand discharge as outlined in previous section on page 11.
3 – With air handler unit panels removed, install sensor bracket assembly to the unit by lining up holes in the center support bracket as shown in FIGURE 9. Note: sensor should be facing toward the inside of the unit.
FIGURE 10 (Detail)
5 – Loop any excess wire through the plastic “M” wire clip located on the inside of the center support bracket.
Horizontal Left Configuration
1 – Remove sensor bracket assembly from vertical position. Do not remove sensor from bracket, and do not disconnect or reroute sensor wire from the control panel area. Set the sensor bracket assembly aside.
2 – Follow instructions for left-hand discharge as outlined in previous section on page 11 and page 12. Instructions are also located on sticker on top of coil assembly.
3 – After coil assembly and center support bracket are reinstalled into unit, with air handler unit panels removed, install sensor bracket assembly to the center support bracket by lining up the holes as shown in FIGURE 11.
FIGURE 9 4 – Ensure sensor wire routes to the right hand side,
as viewed from the front of the unit. The wire must route through the slotted opening in the center support bracket (see FIGURE 10).
Page 13
FIGURE 11
4 – Loop any excess wire through the plastic “M” wire clip located on the inside of the center support bracket.
Downflow Configuration 1 – Remove sensor bracket assembly from vertical position. Do not remove sensor from bracket, and do not disconnect or reroute sensor wire from the control panel area. Set the sensor bracket assembly aside. 2 – Follow the downflow conversion installation instructions located in the downflow installation kit (ordered separately).
NOTE Refer to the downflow kit installation instructions for more details on unit configuration.
3 – With air handler access panels removed, install sensor bracket assembly to the side of the cabinet by lining up holes as shown in FIGURE 12.
FIGURE 12 (Detail) 4 – Loop and bundle any excess sensor wire with a
wire tie.
FIGURE 12
Page 14
Condensate Drain
IMPORTANT
On units of this type, where the blower “draws” rather than “blows” air through the coil, traps must be installed in the condensate drain lines (primary and auxiliary, if used). Traps prevent the blower from drawing air through the drain lines into the air supply.
ABOVE FINISHED SPACE?
NO
OVERFLOW DRAIN LINE
ALWAYS RUN AN OVERFLOW DRAIN LINE. IF NOT POSSIBLE TO ROUTE OVERFLOW DRAIN LINE, INSTALL LOW VOLTAGE OVERFLOW SWITCH KIT. WIRE KIT TO SHUT DOWN COMPRESSOR PER INSTRUCTIONS.
VENT MUST EXTEND ABOVE HEIGHT OF COIL DRAIN PAN BY TWO INCHES (51MM)
VENT
COMPACT OVERFLOW SWITCH WITH 3/4″ FEMALE SLIP INLET AND MALE ADAPTER, TWO PART DESIGN FOR USE WHERE OBSTRUCTIONS PREVENT DIRECT THREADING
CLEAN OUT
PRESS IN (DO NOT GLUE)
YES
AIR HANDLER DRAIN PAN
OVERFLOW DRAIN
MAIN DRAIN
1″ X 3/4″ X 3/4″ REDUCING TEE WITH PLUG
NOTE — WHEN A AIR HANDLER IS LOCATED ABOVE A FINISHED SPACE THE SECONDARY DRAIN PAN MUST HAVE A LARGER FOOTPRINT THAN THE AIR HANDLER.
SECONDARY DRAIN PAN
LENNOX1 P-TRAP 49P66, J-TRAP # 91P90 OR ANY PVC SCH 40 P- OR
J-TRAP 3/4″
2″ (51MM)
WHEN A COIL IS LOCATED ABOVE A FINISHED SPACE, A 3/4″ (19.1MM) SECONDARY DRAIN LINE MUST BE:
CONNECTED TO SECONDARY DRAIN PAN
OR
CONNECTED TO THE OVERFLOW DRAIN OUTLET OF THE AIR HANDLER DRAIN PAN.
TRAPS MUST BE DEEP ENOUGH TO OFFSET MAXIMUM STATIC DIFFERENCES — GENERALLY, TWO INCHES (51MM).
TRAP DEPTH TO APPROVED
DRAIN
FOR NEGATIVE PRESSURE COILS (BLOWER AFTER COIL) TRAPS ARE REQUIRED ON ALL DRAIN LINES CONNECTED TO COIL.
DRAIN LINE SHOULD SLOPE A MINIMUM OF ONE INCH PER 10
FEET (25MM PER 3
METERS)
1 LENNOX P-TRAP 49P66 REQUIRES A LARGER INSTALLATION SPACE THAN THE J-TRAP 91P90. 2 PIPE NIPPLE PROVIDED IN BAG ASSEMBLY – SCH 80, 3/4″ I. D. X 5″ – 34K7401 (1): CUT THE PIPE IN HALF AND USE IT TO ROUTE THE MA IN DRAIN.
FIGURE 13. Typical Main and Overflow Drain
IMPORTANT
A field-fabricated secondary drain pan, with a drain pipe to the outside of the building, is required in all installations over a finished living space or in any area that may be damaged by overflow from the main drain pan. In some localities, local codes may require a secondary drain pan for any horizontal installation.
THIS CORNER SHOULD BE 5/8″ (+/- 1/8″) HIGHER THAN DRAIN CORNER
SLOPING THE UNIT
Make sure the unit is sloped (similar to the slope shown in FIGURE 14) so that the drain pan will empty completely without water standing in the pan.
DRAIN CORNER
LEVEL PLANE
FIGURE 14. Sloping the Unit for Proper Drainage
Page 15
INSTALL CONDENSATE DRAIN The air handler is provided with 3/4″ NPT condensate drain connections.
IMPORTANT
Confirm primary and secondary drains are open. 1 – CBK45UHPT units are equipped with a drain pan,
which includes green (main drain) and red (secondary drain) plugs. Unscrew the plugs to remove them before inserting condensate drain fittings.
ALL CBK45UHPT MODELS
UNSCREW PLUGS AND CONNECT
PROPERLY SIZED FIELD-PROVIDED
FITTINGS AND DRAIN LINES.
DRAIN PAN
RED (SECONDARY) DRAIN PLUG
GREEN (PRIMARY) DRAIN PLUG
FIGURE 15. Drain Line Connections
2 – Install properly sized, field-provided connection fittings and connect primary drain line to the main drain pan connection.
NOTE – When installing drain line connection fittings to the drain pan, hand tighten the fitting and use a thread sealant. Over-tightening the fittings can split connections on the drain pan.
3 – If the secondary drain line is to be used, remove the plug or the knockout and route the drain line so that water draining from the outlet will be easily noticed by the homeowner. Refer to local codes for drain trap requirements on the secondary drain line.
4 – Check again to ensure drain ports and drain pan are free of all debris.
5 – Plug and check any unused drain pan openings for tightness. Torque plugs to 30 in. lb. to prevent water leaks or seepage from the drain pan.
6 – Install a 2″ trap in the main (primary) drain lines as close to the unit as practical (see FIGURE 14). Make sure the top of the trap is below the connection to the drain pan to allow complete drainage of the pan.
NOTE – Horizontal runs must have an anti-siphon air vent (standpipe) installed ahead of the horizontal run.
See FIGURE 14. An extremely long horizontal run may
require an oversized drain line to eliminate air traps.
NOTE – Do not operate air handler without a trap in the main (primary) drain. The condensate drain is on the negative pressure side of the blower; therefore, air being pulled through the condensate line will not allow positive drainage without a proper trap.
7 – Route the drain line to the outside or to an appropriate drain. Drain lines must be installed so they do not block service access to the front of the air handler. A 24″ clearance is required for filter, coil, or blower removal and service access.
NOTE – Check local codes before connecting the drain line to an existing drainage system. Insulate the drain lines where sweating could cause water damage.
TEST CONDENSATE DRAIN
Test the drain pan and drain line after installation:
1 – Pour several quarts of water into drain pan. Use enough water to fill both the drain trap and the line.
2 – Check the installed drain pan. Drain pan must be draining completely. Drain line fittings must not be leaking. Water must be draining from the end of the primary drain line.
3 – Correct any leaks found.
Duct System and Filters
DUCT SYSTEM
The air handler is provided with flanges for the connection of the supply plenum.
Supply and return duct system must be adequately sized to meet the system’s air requirements and static pressure capabilities. The duct system should be insulated with a minimum of 1″ thick insulation with a vapor barrier in conditioned areas or 2″ minimum in unconditioned areas.
Supply plenum should be the same size as the flanged opening provided around the blower outlet and should extend at least 3 ft. from the air handler before turning or branching off plenum into duct runs. The plenum forms an extension of the blower housing and minimizes air expansion losses from the blower.
FILTERS
A filter is provided. TABLE 2 lists the filter size for each unit.
TABLE 2. Unit Air Filter Size Chart
CBK45UHPT
Filter Size In.
-018, -024, -030
15″ x 20″ x 1″
-036, -042
18″ x 20″ x 1″
IMPORTANT
If a high efficiency filter is being installed as part of this system to ensure better indoor air quality, the filter must be properly sized. High efficiency filters have a higher static pressure drop than standard efficiency glass/foam filters. If the pressure drop is too great, system capacity and performance may be reduced. The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer, resulting in an increase in the number of service calls. Before using any filter with this system, check the specifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifications bulletin. Additional information is provided in Service and Application Note ACC002 (August 2000)..
Page 16
INSTALLING DUCT SYSTEM
Connect supply air duct to the flange on top of the air handler. If an isolation connector is used, it must be nonflammable.
FIELD-FABRICATED RETURN AIR DUCT FLANGE FOR HORIZONTAL APPLICATIONS
A return air duct system is recommended, but not factory-provided. If the unit is installed in a confined space or closet, run a full-size return connection to a location outside the closet.
Cabinet and Duct Flange
CABINET DOOR FLANGE
1-1/2 (38)
DUCT
FLANGE
3/4
(19)
3/4 (19)
1-1/2(38)
3/4 (19)
“A”
BRAKE DOWN 90 DEGREES
1/2
1/4 (6) DIA.
(13)
2-HOLES
UNIT SIZE
-018, -024, -030
-036, -042
“A”
18-3/8″ 21-1/2″
BOTTOM OF CABINET
DUCT ADAPTER
3/4 (19)
1-1/2 (38)
FIGURE 16. Cabinet and Duct Flange
Brazing Refrigerant Lines
IMPORTANT
Braze-free fittings must conform with UL207 or ISO14903 (latest edition).
Refrigerant lines must be connected by a qualified technician in accordance with established procedures.
IMPORTANT
Refrigerant lines must be clean, dry, refrigerant-grade copper lines. Air handler coils should be installed only with specified line sizes for approved system combinations. Handle the refrigerant lines gently during the installation process. Sharp bends or kinks in the lines will cause a restriction. Do not remove the caps from the lines or system connection points until connections are ready to be completed.
WARNING
Polyol ester (POE) oils used with HFC-410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections.
WARNING
Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture. Check the high and low pressures before applying heat.
WARNING
When using a high pressure gas such as nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).
CAUTION
Brazing alloys and flux contain materials which are hazardous to your health. Avoid breathing vapors or fumes from brazing operations. Perform operations only in well-ventilated areas. Wear gloves and protective goggles or face shield to protect against burns. Wash hands with soap and water after handling brazing alloys and flux.
IMPORTANT
To prevent the build-up of high levels of nitrogen when purging, it must be done in a well-ventilated area. Purge low-pressure nitrogen (1 to 2 psig) through the refrigerant piping during brazing. This will help to prevent oxidation and the introduction of moisture into the system.
Refrigerant system installations shall be installed and tested per ASHRAE Standard 15.2, Section 10.0 (latest edition).
Page 17
NOTE – When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and Fabrication Guidelines, CORP. 9351-L9, or contact Lennox Technical Support Product Applications for assistance. To obtain the correct information from Lennox, be sure to communicate the following information: Model and capacity.
1 – Route the suction and liquid lines from the fittings on the indoor coil to the fittings on the outdoor unit. Run the lines in a direct path, avoiding unnecessary turns and bends.
2 – Make sure that the suction line is insulated over the entire exposed length and that neither suction nor liquid lines are in direct contact with floors, walls, duct system, floor joists, or other piping.
3 – To avoid damaging the rubber grommets in the cabinet while brazing, slide the rubber grommets over the refrigerant lines until they are away from the heat source.
NOTE – Place wet rags against piping plate, piping stubs and expansion valve.
4 – Connect the suction and liquid lines to the evaporator coil. Take care to protect the cabinet and internal components as detailed in FIGURE 17.
5 – Braze using an alloy of silver or copper and phosphorus with a melting point above 1,100°F (593°C).
NOTE – Do not use soft solder.
6 – Allow refrigerant pipes to cool to room temperature.
NOTE – Make sure to route copper refrigerant tubing away from sharp edges and make sure that it does not touch other metal surfaces. This prevents damage caused by vibration or metal-on-metal contact.
7 – Reinstall the rubber grommets into the refrigerant piping panel.
NOTE – Make sure expansion valve capillary tube is not touching metal edges or copper tubing.
8 – Make sure outdoor unit has been placed according to the Installation Instructions and is connected to the refrigerant lines
Multiple Systems Installed in Same Space
If multiple systems are installed in the same confined space, and at least one of the systems has A2L refrigerant and an exposed joint (not covered by line set sleeve), then all non-direct vent furnaces in the same space must have a refrigerant detection system with a sensor installed below the level of the burners.
If refrigerant sensor is required, it shall be mounted as follows:
Upflow Applications: Mounted on an unused side furnace return air connection at least 9 inches above the floor and within 9 inches from front of furnace.
Horizontal Applications: Mounted on the lower section of the side return furnace air connection, within 9 inches of both the blower deck and front of furnace.
Downflow Applications: Mounted on one side of the evaporator coil 9 inches above the floor and within 9 inches from front of coil.
Braze-Free Applications
1 – Remove bell from the stubbed connection using a tubing cutter.
2 – Position the refrigerant piping and follow the assembly instructions provided with the braze free connector.
IMPORTANT
After completion of field piping for split systems, the field pipework shall be pressure tested with an inert gas and then vacuum tested prior to refrigerant charging, according to the following requirements;
Field-made refrigerant joints indoors shall be tightness tested. The test method shall have a sensitivity of 5 grams per year of refrigerant or better under a pressure of at least 0,25 times the maximum allowable pressure marked on unit nameplate.
No leak shall be detected.
Page 18
PLEASE READ IMPORTANT ISSUES CONCERNING BRAZING OPERATIONS ON PREVIOUS PAGES BEFORE PROCEEDING.
NOTE – REFER TO OUTDOOR UNIT INSTALLATION INSTRUCTIONS FOR REFRIGERANT PIPING SIZE REQUIREMENTS.
NOTE – Use silver alloy brazing rods with five or six percent minimum silver alloy for copper-to-copper brazing, 45 percent alloy for copper-to-brass and copper-to-steel brazing.
A REMOVE ACCESS PANEL
B REMOVE RUBBER PLUG FROM BOTH LIQUID AND SUCTION LINES NOTE – CBK45 SERIES UNITS USE NITROGEN OR DRY AIR AS A HOLDING CHARGE. IF THERE IS NO PRESSURE WHEN THE RUBBER PLUGS ARE REMOVED, CHECK THE COIL FOR LEAKS BEFORE INSTALLING.
C EITHER REMOVE OR PUSH PIPE WRAPPING BACK THROUGH HOLE IN PIPING PLATE BEFORE LINE SET CONNECTION AND BRAZING.
LOW
PIPING PLATE
HIGH
D CONNECT PIPES
NOTE – REFRIGERANT LINE SETS SHOULD BE ROUTED TO ALLOW FILTER ACCESSIBILITY.
E CONNECT GAUGES AND START NITROGEN FLOW
FLOW REGULATED NITROGEN (AT 1 TO 2 PSIG) THROUGH THE REFRIGERATION GAUGE SET INTO THE VALVE STEM PORT CONNECTION ON THE OUTDOOR UNIT LIQUID LINE SERVICE VALVE AND OUT OF THE VALVE STEM PORT CONNECTION ON THE SUCTION SERVICE VALVE.
NITROGEN
F PLACE A WET RAG AGAINST PIPING PLATE AND AROUND THE SUCTION LINE CONNECTION.
G BRAZE CONNECTION. ALLOW PIPE TO COOL BEFORE REMOVING WET RAG FROM CTXV SENSING BULB AND PIPING PANEL AREA.
H REPEAT PREVIOUS PROCEDURE FOR LIQUID LINE.
REFER TO INSTRUCTIONS PROVIDED WITH OUTDOOR UNIT FOR LEAK TESTING, EVACUATING AND CHARGING PROCEDURES. REFRIGERANT SYSTEM INSTALLATIONS SHALL BE INSTALLED AND TESTED PER ASHRAE STANDARD 15.2, SECTION 10.0 (LATEST EDITION).
FIGURE 17. Brazing Connections
Page 19
Sealing the Unit
Seal the unit so that warm air is not allowed into the cabinet. Warm air introduces moisture, which results in water blow-off problems. This is especially important when the unit is installed in an unconditioned area. If installed in an unconditioned space, sealant should be applied around the electrical wires, refrigerant tubing, and condensate lines where they enter the cabinet.
WARNING
There must be an airtight seal between the bottom of the air handler and the return air plenum. Use fiberglass sealing strips, caulking, or equivalent sealing method between the plenum and the air handler cabinet to ensure a tight seal. Return air must not be drawn from a room where this air handler or any gas-fueled appliance (i.e., water heater), or carbon monoxide-producing device (i.e., wood fireplace) is installed.
IMPORTANT
Use duct tape and/ or Permagum to seal closed any space around the holes where the drain lines exit the cabinet. Warm air must not be allowed to enter through any gaps or holes in the cabinet.
Electrical Connections
WARNING
Electric shock hazard! – Disconnect all power supplies before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
WARNING
Run 24V Class II wiring only through specified low voltage opening. Run line voltage wiring only through specified high voltage opening. Do not combine voltage in one opening.
WARNING
Electric Shock Hazard. Can cause injury or death. Unit must be properly grounded in accordance with national and local codes. Line voltage is present at all components when unit is not in operation on units with single-pole contactors. Disconnect all remote electric power supplies before opening access panel. Unit may have multiple power supplies.
WARNING
Electric Shock Hazard.
Can cause injury or death.
Foil-faced insulation has conductive characteristics similar to metal. Be sure there are no electrical connections within 1/2 of the insulation. If the foil-faced insulation comes in contact with electrical voltage, the foil could provide a path for current to pass through to the outer metal cabinet. While the current produced may not be enough to trip existing electrical safety devices (e.g., fuses or circuit breakers), the current can be enough to cause an electrical shock hazard that could cause personal injury or death.
· Wiring must conform to the current National Electric Code ANSI/NFPA No. 70, or Canadian Electric Code Part I, CSA Standard C22.1, and local building codes. Refer to following wiring diagrams. See unit nameplate for minimum circuit ampacity and maximum over-current protection size.
· Electrical wiring, disconnect means and over-current protection are to be supplied by the installer. Refer to the air handler rating plate for maximum over-current protection, minimum circuit ampacity, as well as operating voltage. Select the proper supply circuit conductors in accordance with tables 310-16 and 310-17 in the National Electric Code, ANSI/NFPA No. 70 or table 1 through table 4 in the Canadian Electric Code, Part I, CSA Standard C22.1.
· The power supply must be sized and protected according to the specifications supplied on the product.
· This air handler is factory-configured for 240 volt, single phase, 60 cycles. For 208-volt applications, see “208 Volt Conversion” later in this section.
· Separate openings have been provided for 24V low voltage and line voltage. Refer to the dimension illustration of specific location.
· This unit is provided with holes for conduit. Use provided caps to seal holes not used.
· Typical unit wiring (as well as wiring of optional field-installed electric heat) is given in FIGURE 1. Refer to the instructions provided with the electric heat section for proper installation.
Page 20
WARNING
USE COPPER CONDUCTORS ONLY
1 – Disconnect all power supplies.
2 – Remove the air handler access panel.
3 – Route the field supply wires to the air handler electrical connection box.
4 – Use UL-listed wire nuts to connect the field supply conductors to the unit black and yellow leads, and the ground wire to ground terminal marked GND.
5 – 5. Replace the air handler access panel.
Note: Do not remove and relocate the transformer mounting bracket from the factory position.
208 VOLT CONVERSION
1 – Disconnect all power supplies.
2 – Remove the air handler access panel.
3 – Using the wiring diagram located on the unit access panel as a reference, move the two connected black transformer leads from the 240 volt terminal on the transformer to the 208 volt terminal on the transformer.
WARNING
Electrically ground air handler. Connect ground wire to ground terminal marked “GND”. Failure to do so can result in death or electrical shock.
208 / 240 VOLT TRANSFORMER
PRIMARY
SECONDARY
240 Volts 208 Volts
FIGURE 18. Converting Unit from 240VAC to 208VAC
Check-out Procedures
NOTE Refer to outdoor unit installation instructions for system start-up instructions and refrigerant charging instructions. PRE-START-UP CHECKS · Is the air handler properly and securely installed? · If horizontally configured, is the unit sloped up to 5/8
inch toward drain lines? · Will the unit be accessible for servicing? · Has an auxiliary pan been provided under the unit with
separate drain for units installed above a finished ceiling or in any installation where condensate overflow could cause damage?
· Have ALL unused drain pan ports been properly plugged?
· Has the condensate line been properly sized, run, trapped, pitched, and tested?
· Is the duct system correctly sized, run, sealed, and insulated?
· Have all cabinet openings and wiring been sealed? · Is the indoor coil factory-installed TXV properly sized for
the outdoor unit being used?
· Have all unused parts and packaging been disposed of?
· Is the filter clean, in place, and of adequate size?
· Is the wiring neat, correct, and in accordance with the wiring diagram?
· Is the unit properly grounded and protected (fused)?
· Is the thermostat correctly wired and in a good location?
· Are all access panels in place and secure?
CHECK BLOWER OPERATION · Set thermostat to FAN ON.
· The indoor blower should come on.
CHECK COOLING OPERATION
· Set thermostat to force a call for cooling (approximately 5ºF lower than the indoor ambient temperature).
· The outdoor unit should come on immediately and the indoor blower should start between 30 – 60 seconds later.
· Check the air flow from a register to confirm that the system is moving cooled air.
· Set the thermostat 5ºF higher than the indoor temperature. The indoor blower and outdoor unit should cycle off.
CHECK ELECTRIC HEAT (IF USED)
· Set thermostat to call for auxiliary heat (approximately 5°F above ambient temperature). The indoor blower and auxiliary heat should come on together. Allow a minimum of 3 minutes for all sequencers to cycle on.
· Set the thermostat so that it does not call for heat. Allow up to 5 minutes for all sequencers to cycle off.
Page 21
Operation
TIME DELAY RELAY
Blower time delay operation:
1 – When cooling demand is initiated, there is a 1 second motor-on delay.
2 – After the motor-on delay expires, motor ramps up to 100% and runs at 100% until cooling demand is satisfied.
3 – Once demand is met, motor runs at 100% for 45 seconds.
4 – Motor ramps down to stop.
3
4
12
100% CFM
100% CFM
OFF 1
SECOND DELAY
COOLING DEMAND
45 SECS
FIGURE 19. Blower Time Delay
COOLING (COOLING ONLY OR HEAT PUMP)
When the thermostat calls for cooling, 24 volts is put on the blower time-delay relay coil and then the indoor blower relay energizes. The normally open contacts close, causing the indoor blower motor to operate. The circuit between R and Y is completed, closing the circuit to the contactor in the outdoor unit, starting the compressor and outdoor fan motor.
On heat pumps, circuit R and O energizes the reversing valve, switching the valve to the cooling position. (The reversing valve remains energized as long as the thermostat selector switch is in the COOL position.)
At the completion of the cooling demand the indoor blower and outdoor unit should cycle off. Air handler should cycle off 45 seconds after the outdoor unit shuts off.
HEATING (ELECTRIC HEAT ONLY)
When the thermostat calls for heat, the circuit between R and W is completed, and the heat sequencer is energized. A time delay follows before the heating elements and the indoor blower motor come on. Units with a second heat sequencer can be connected with the first sequencer to W on the thermostat sub-base, or they may also be connected to a second stage on the sub-base.
HEATING (HEAT PUMP)
When the thermostat calls for heating, 24 volts is applied to the blower time-delay relay coil. Then, normally open contacts close, causing the indoor blower motor to operate. The circuit between R and Y is completed, closing the circuit to the contactor in the outdoor unit, starting the compressor and outdoor fan motor.
If the room temperature continues to decrease, the circuit between R and W1 is completed by the second-stage heat room thermostat. Circuit R-W1 energizes a heat sequencer. The completed circuit will energize supplemental electric heat (if applicable). Units with a second heat
sequencer can be connected with the first sequencer to W1 on the thermostat. They may also be connected to a second heating stage W2 on the thermostat sub-base.
EMERGENCY HEAT (HEATING HEAT PUMP)
If the selector switch on the thermostat is set to the emergency heat position, the heat pump will be locked out of the heating circuit, and all heating will be electric heat (if applicable). A jumper should be placed between W2 and E on the thermostat sub-base so that the electric heat control will transfer to the first-stage heat on the thermostat. This will allow the indoor blower to cycle on and off with the electric heat when the fan switch is in the AUTO position.
Homeowner Maintenance
IMPORTANT
Do not operate system without a filter. A filter is required to protect the coil, blower, and internal parts from excessive dirt and dust. The filter is placed in the return duct by the installer.
· Inspect air filters at least once a month and replace or clean as required. Dirty filters are the most common cause of inadequate heating or cooling performance.
· Replace disposable filters. Cleanable filters can be cleaned by soaking in mild detergent and rinsing with cold water.
· Install new/clean filters with the arrows on the side pointing in the direction of air flow. Do not replace a cleanable (high velocity) filter with a disposable (low velocity) filter unless return air system is properly sized for it.
· If water should start coming from the secondary drain line, a problem exists which should be investigated and corrected. Contact a qualified service technician.
Page 22
Repairing or Replacing Cabinet Insulation
IMPORTANT
DAMAGED INSULATION MUST BE REPAIRED OR REPLACED before the unit is put back into operation. Insulation loses its insulating value when wet, damaged, separated or torn.
Matte- or foil-faced insulation is installed in indoor equipment to provide a barrier between outside air conditions (surrounding ambient temperature and humidity) and the varying conditions inside the unit. If the insulation barrier is damaged (wet, ripped, torn or separated from the cabinet walls), the surrounding ambient air will affect the inside surface temperature of the cabinet. The temperature/humidity difference between the inside and outside of the cabinet can cause condensation on the inside or outside of the cabinet which leads to sheet metal corrosion and, subsequently, component failure.
REPAIRING DAMAGED INSULATION Areas of condensation on the cabinet surface are an indication that the insulation is in need of repair. If the insulation in need of repair is otherwise in good condition, the insulation should be cut in an X pattern, peeled open, glued with an appropriate all-purpose glue and placed back against the cabinet surface, being careful to not overly compress the insulation so the insulation can retain its original thickness. If such repair is not possible, replace the insulation. If using foil-faced insulation, any cut, tear, or separations in the insulation surface must be taped with a similar foil-faced tape.
GLUE – Make sure there is full coverage of glue on the metal or insulation so there are no areas where air pockets may form which can lead to sweating.
Professional Maintenance
NOTICE !
Failure to follow instructions will cause damage to the unit.
This unit is equipped with an aluminum coil. Aluminum coils may be damaged by exposure to solutions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a moderate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning.
In coastal areas, the coil should be cleaned with potable water several times per year to avoid corrosive buildup (salt).
Use of Air Handler During Construction
Lennox does not recommend the use of its air handler unit during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit. Air handler units may be used for heating or cooling of buildings under construction, if the following conditions are met: · A room thermostat must control the air handler. The use
of fixed jumpers is not allowed.
· Air filter must be installed in the system and must be maintained during construction.
· Air filter must be replaced upon construction completion.
· The air handler evaporator coil, supply fan assembly and duct system must be thoroughly cleaned following final construction clean-up.
· All air handler operating conditions must be verified according to these installation instructions.
· Ensure that sensor opening is clear and free of debris.
1. CUT INSULATION IN X PATTERN 2. APPLY GLUE 3. PRESS GLUED TABS AGAINST CABINET
FIGURE 20. Repairing Insulation
FIGURE 21. Example of Clear, Unobstructed Sensor Inlet
Page 23
Sensor Maintenance
It is recommended to check the state of the sensor every 6 months, at the beginning of each cooling and heating season.
· Ensure that the sensor opening is clear and free of debris.
· Check that the sensor cable is in good condition.
· DO NOT use abrasive cleaning solutions or detergents to clean sensor opening.
· DO NOT use flammable compressed air solutions to clean the sensor opening.
· DO NOT vacuum sensor inlet opening, as this could cause damage to the sensor internal components.
· Replace sensor if the opening is not clean or free of debris
· When cleaning the evaporator coil, remove sensor from the coil. Follow recommended coil cleaning guidelines as described in installation instructions.
Modes of Operation
The modes of operation for the RDS Non-Communicating Blower Control Board are Initializing, Normal, Leak Detected, and Fault.
Initializing The RDS Non-Communicating Blower Control Board is establishing connection with the refrigerant detection sensor and is completing an initial five (5) minute purge sequence.
Normal The HVAC system is functioning normally. The RDS Non-Communicating Blower Control Board has not detected a refrigerant leak.
Leak Detected When the RDS Non-Communicating Blower Control Board detects a refrigerant leak: 1 – The RDS Non-Communicating Blower Control Board
shuts off the (R) input (24VAC power) to the thermostat, which de-energizes the outdoor unit compressor and heat sources, such as gas and/or electric strip heat. No heating or cooling demands will be met.
2 – The RDS Non-Communicating Blower Control Board activates the blower (high speed). The blower purges refrigerant from the cabinet, plenum, and ductwork.
3 – After the RDS Non-Communicating Blower Control Board determines the refrigerant levels are below the safety threshold, the blower will continue to function for an additional seven (7) minutes.
4 – After the blower sequence is complete, the HVAC system resumes normal operation.
NOTE The HVAC system may not maintain a cooling or heating setpoint if a significant leak exists. Any refrigerant leaks that remain unaddressed for an extended time may cause the HVAC system to shut down on a low refrigerant pressure limit condition.
Fault
When a fault is detected within the RDS Non-Communicating Blower Control Board, the indoor unit blower engages and remains engaged at a constant output until the fault is cleared.
Diagnostic Codes
The RDS Non-Communicating Blower Control Board is equipped with a multicolor LED within its enclosure. The LED signals the state of the RDS Non-Communicating Blower Control Board.
See TABLE 3 to review the diagnostic codes.
TABLE 3. LED Diagnostic Codes
State
LED Diagnostic Code
Action
Initializing Monitoring
Mitigating (Leak Detected)
Flashing green¹ Solid green with blue
flash²
Flashing blue
Not Applicable
Not Applicable
Check coil tubes for leak. Repair the issue and restart the equipment.
Fault/Service
Solid blue, interrupted by Refer to TABLE 8 for trou-
issue flash code
bleshooting steps.
1. A rapid flash indicates the RDSC is in the process of sensor enumeration 2. A blue flash indicates the mitigation process has previously occurred.
Red LED Diagnostic Codes
Red diagnostic codes indicate a specific RDS Non-Communicating Blower Control Board issue. Yellow diagnostic codes indicate the sensor’s position (if applicable).
Red Flash
1 2
3 4
5
TABLE 4. Red LED Diagnostic Codes
Applies to Individual Sensor(s)
Yes
No
Yes
Yes
No
Issue
Action
Sensor indicates fault
Replace the sensor (Cat. # 26Z69)
Check if drain line float switch is installed. If no
Float switch Active float switch is installed, check jumper on control board.
Incompatible sensor type
Replace with a compatible sensor
(Cat. # 26Z69)
Sensor communications issue
Check sensor connection. Ensure connection
is clean and tight.
Check for 24VAC power
connection to the R
R-input not available
terminal inputs on the RDSC. R-inputs must
be energized for the
RDSC to function.
Page 24
Test Button Functionality
The RDS Non-Communicating Blower Control Board is equipped with a Test/Reset button. The Test button can be used to complete several functions, depending on the mode of operation of the RDS Non-Communicating Blower Control Board.
TABLE 5 lists the functions of the Test button during each mode of operation.
TABLE 5. Test Button Function
Mode of Operation
Normal
Press the Test Button to…
Trigger a leak detection response. Verify all equipment is wired correctly into the RDSC (after installation).
Leak Detected
Reset the RDSC to a normal mode of operation after a previous leak has been detected and purged from the HVAC system.
Fault
Reset the RDSC after troubleshooting and resolving a fault condition. If the fault is not resolved, the RDSC will enter the Fault mode again.
Test Button – Additional Functions
TABLE 6 lists the additional functions of the Test Button while the RDS Non-Communicating Blower Control Board is functioning within the states of Initializing, Monitoring, Leak Detection, Servicing and Fault. Refer to “TABLE 3. LED Diagnostic Codes” on page 24.
TABLE 6. Additional Button Functions
State Initializing
Press Short
Action
Skips remaining pre-purge after sensors are recognized by the RDSC
Initializing Monitoring
Monitoring Mitigating Servicing
Servicing Fault
Fault
Long Short
Long Short Short
Long Short
Long
Reset control Clear purge-counter if prior mitigation has occurred; Test mitigation
Reset control If testing mitigation, end test
Reevaluate fault condition – if cleared return to monitoring, otherwise update indicator
Reset control Reevaluate fault condition – if cleared return to monitoring, otherwise update indicator
Reset control
Thermostat Compatibility
Thermostats that preserve memory settings are compatible with the RDS Non-Communicating Blower Control Board. Examples include:
· Battery-powered thermostats
· Analog thermostats
· Smart thermostats
· Late-model programmable thermostats
· Early-generation digital and programmable thermostats may not retain the operation mode and temperature setpoints after a power outage.
The following scenarios are likely to occur when home occupants are not available to adjust the thermostat setpoints as the system is recovering from leak detection and resuming normal operation:
· Heating could be lost during a cold night
· Cooling could be lost during a hot day
· The thermostat could reset to an incorrect temperature setpoint
Compatibility Verification Complete the following process to determine whether the thermostat is compatible with the RDS Non-Communicating Blower Control Board. 1 – Change the thermostat’s current setpoint and operating mode.
2 – Power cycle the breaker to the furnace. NOTE Wait five (5) minutes before supplying power to the furnace breaker.
3 – Note whether the thermostat maintained its setpoints and operating mode.
a. If the thermostat maintained the settings, the thermostat is compatible with the RDS NonCommunicating Blower Control Board.
b. If the thermostat did not maintain its setpoint and/ or operating mode, the thermostat is not compatible with the RDS Non-Communicating Blower Control Board. Recommend replacing with a compatible thermostat.
Page 25
Additional Applications
In zoned applications, all dampers will remain open when the RDS Non-Communicating Blower Control Board is in Fault or Leak Detected mode. Normal heating and cooling demands are permissible, but the blower will remain engaged until the fault condition is addressed.
Zone HVAC System If the RDS Non-Communicating Blower Control Board is installed in a zone HVAC system, the RDS Non-Communicating Blower Control Board will open all zone dampers if a leak is detected.
NOTE Proper wiring of the zone panel to the RDS Non-Communicating Blower Control Board is required for all zone dampers to open.
After the purge sequence is complete, the zone system will resume normal operation.
External Alarm (For applications with external alarms wired directly to the RDS Non-Communicating Blower Control Board.)
The RDS Non-Communicating Blower Control Board triggers the external alarm system when it enters Leak Detected mode. For alarm notifications, the RDS Non-Communicating Blower Control Board provides a dry relay contact that is rated 3A at 30 VAC/DC.
Start Up Test Procedure
The RDS Non-Communicating Blower Control Board is equipped with a Test/Reset button, see “Test Button Functionality” on page 25 After the RDS Non-Communicating Blower Control Board has been mounted and wired, restore power to the HVAC system. The system will then run through a purge sequence for five (5) minutes. After the purge sequence is complete, proceed to testing cooling demand and heating demand.
Cooling Demand 1 – Prompt a cooling demand at the thermostat.
2 – Press the Test button on the RDS Non-Communicating Blower Control Board.
The system then executes a leak detection response.
3 – Observe the following sequence:
a. The LED indicator flashes the sequence for leak detection (flashing blue).
b. The blower powers up. c. The outdoor compressor powers down. 4 – Press the Test button to terminate the simulated Leak
Detected mode upon test completion.
Heating Demand 1 – Prompt a heating demand at the thermostat.
2 – Press the Test button on the RDS Non-Communicating Blower Control Board.
The system then executes a leak detection response.
3 – Observe the following sequence:
a. The LED indicator flashes the sequence for leak detection (flashing blue).
b. The blower powers up. c. The gas burners power down. d. The outdoor compressor powers down. 4 – Press the Test button to terminate the simulated Leak
Detected mode upon test completion.
The installation of the RDS Non-Communicating Blower Control Board is complete after both sequences are successfully completed.
Page 26
Diagnostic Codes and Troubleshooting
State
TABLE 7. LED Diagnostic Codes
LED Diagnostic Code
Action Required
Initializing
Monitoring Mitigating (Leak Detected) Fault/Service
Red Flash 1 2 3 4 5
Flashing green
Solid green. If a prior mitigation occurred, a blue flash
interrupts the solid green LED.
Flashing blue
Solid blue, interrupted by issue diagnostic code
None
None
Check coil tubes for leak. Repair the issue and restart the equipment.
Refer to TABLE 8 for troubleshooting steps.
TABLE 8. Red LED Diagnostic Codes / Troubleshooting
Applies to Individual Sensor(s)
Issue
Action Required
Yes
Sensor indicates fault
Replace the sensor
Check if drain line float switch is installed. If
No
Float switch Active
no float switch is installed, check jumper on
control board.
Yes
Incompatible sensor type
Replace the sensor
Yes
Sensor communications issue
Check sensor connection. Ensure connection is clean and tight.
No
R-input not available
Check sensor connections. Ensure connection is clean and tight.
Decommissioning
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refrigerants are recovered safely.
Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of recovered refrigerant. It is essential that electrical power is available before starting decommissioning.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure, ensure that:
· mechanical handling equipment is available, if required, for handling refrigerant cylinders;
· all personal protective equipment is available and being used correctly;
· the recovery process is supervised at all times by a competent person;
· recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with instructions.
h) Do not overfill cylinders (no more than 80% volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another REFRIGERATING SYSTEM unless it has been cleaned and checked.
IMPORTANT
Equipment shall be labelled stating that it has been decommissioned and emptied of refrigerant. The label shall be signed and dated. Ensure that there are labels on the equipment that state the flammability of the refrigerant used.
Page 27
Installing Contractor’s Name_______________________ Installing Contractor’s Phone_______________________ Job Address____________________________________
Installing Date_______________________________ Air Handler Model #___________________________
SUPPLY AIR
Thermostat 9
Disconnect Switch
Line Voltage 3
8
1
Duct System
Temperature
5
2 Integrated Control
6 Blower Motor Amps 7 Electric Heat Amps
Duct Static
RETURN AIR
Filter
4 Drain Line
1 DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary) Registers Open and Unobstructed RETURN AIR DUCT Sealed Filter Installed and Clean Registers Open and Unobstructed
2 INTEGRATED CONTROL Jumpers Configured Correctly (if applicable) Appropriate Links in Place (if applicable)
3 VOLTAGE CHECK Supply Voltage ___________ Low Voltage _____________ Electrial Connections Tight
4 DRAIN LINE Leak Free
5 TOTAL EXTERNAL STATIC (dry coil) dry coil wet coil
Supply External Static ______ ______ Return External Static ______ ______ Total External Static = ______ ______ 6 ELECTRIC HEAT AMPS____________ 7 INDOOR BLOWER AMPS___________ INDOOR BLOWER CFM____________ 8 TEMPERATURE DROP (Cooling Mode) Return Duct Temperature ___________ Supply Duct Temperature – ___________
Temperature Drop = ___________ 8 TEMPERATURE RISE (Heating Mode)
Return Duct Temperature __________ Supply Duct Temperature – __________
Temperature Rise = __________ 9 THERMOSTAT
Adjusted and Programmed Operation Explained to Owner
Explained Operation of System to Homeowner
Technician’s Name:_______________________Date Start-Up & Performance Check Completed__________ FIGURE 22. Start-up and Performance Checklist (Upflow Configuration)
Page 28
Installing Contractor’s Name_______________________ Installing Date_______________________________
Installing Contractor’s Phone_______________________ Air Handler Model #___________________________
Job Address____________________________________
1 Duct System
2 Integrated Control
Filter
Thermostat 9
Disconnect Switch
Line Voltage 3
1 Duct System
RETURN AIR
SUPPLY AIR
4 Drain Line
5 8
Duct Static
Temperature
6 Electric Heat Amps 7 Blower motor Amps
1 DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary) Registers Open and Unobstructed RETURN AIR DUCT Sealed Filter Installed and Clean Registers Open and Unobstructed
2 INTEGRATED CONTROL Jumpers Configured Correctly (if applicable) Appropriate Links in Place (if applicable)
3 VOLTAGE CHECK Supply Voltage ___________ Low Voltage _____________ Electrial Connections Tight
4 DRAIN LINE Leak Free
5 TOTAL EXTERNAL STATIC (dry coil) dry coil wet coil
Supply External Static ______ ______ Return External Static ______ ______ Total External Static = ______ ______ 6 ELECTRIC HEAT AMPS____________ 7 INDOOR BLOWER AMPS___________ INDOOR BLOWER CFM____________ 8 TEMPERATURE DROP (Cooling Mode) Return Duct Temperature ___________ Supply Duct Temperature – ___________
Temperature Drop = ___________ 8 TEMPERATURE RISE (Heating Mode)
Return Duct Temperature __________ Supply Duct Temperature – __________
Temperature Rise = __________ 9 THERMOSTAT
Adjusted and Programmed Operation Explained to Owner
Explained Operation of System to Homeowner
Technician’s Name:_______________________Date Start-Up & Performance Check Completed__________ FIGURE 23. Start-Up and Performance Checklist (Horizontal Configuration)
Page 29
Documents / Resources
 |
LENNOX CBK45UHPT Multi Position Air Handlers [pdf] Instruction Manual 508437-01, CBK45UHPT Multi Position Air Handlers, CBK45UHPT, Multi Position Air Handlers, Position Air Handlers, Air Handlers, Handlers |