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Lennox Merit Series CBK45UHVT Air Handler Installation Instructions
Installation Instructions for Lennox models including: Lennox, Merit Series, CBK45UHVT, Air Handler, Installation Instructions, HVAC, R410A, 508471-01, Lennox Industries Inc.
Lennox Technical Publications [PDF] INSTALLATION INSTRUCTIONS - Lennox 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 ...
508471-01 ©2024 Lennox Industries Inc. Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE
IMPORTANT
If installing in an R454B application, R454B air handler sensor kit (27J27), Refrigerant Detection System Control (27A02) and R454B TXV (26Z70, 26Z71, or 26Z72) must be ordered. If installing in R454B application, use installation instructions provided in R454B air handler sensor kit (27J27). For sensor maintenance recommendations, refer to the instructions in kit 27J27.
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.
WARNING
Maximum Altitude of application is 3200m above sea level. Disponible en español en LennoxPros.com Disponible en Français sur le LennoxPros.com site
INSTALLATION INSTRUCTIONS
Merit® Series CBK45UHVT Air Handler Units R410A
MULTI-POSITION AIR HANDLERS 508471-01 6/2024
Table of Contents
General Information ........................................................2 Wiring Diagrams..............................................................3 BDC3 Blower Control .....................................................5 Adjusting the Blower Speed ...........................................5 Electrical Connections ..................................................10 Requirements ...............................................................12 Unit Dimensions Upflow ............................................13 Unit Dimensions Horiz. ..............................................14 Installation Clearances .................................................15 Installation ....................................................................15 Condensate Drain.........................................................18 Duct System and Filters ..............................................19 Brazing Refrigerant Lines .............................................20 Sealing the Unit ............................................................23 Check-out Procedures ..................................................23 Maintenance .................................................................23 Repairing or Replacing Cabinet Insulation ...................24 Professional Maintenance ............................................24 Use of Air Handler During Construction .......................24 Decommissioning .........................................................25
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.
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.
Page 1
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.
General Information
The CBK45UHVT series air handler with all-aluminum coil is designed for indoor installation only. As shipped, the unit is ready for installation in either upflow or horizontal right-hand air discharge applications. Horizontal drain pan may be repositioned in the field to allow installation in the horizontal left-hand air discharge position. Electric heat, downflow conversion kits, air filters and other accessories are available and listed in the CBK45UHVT Product Specification bulletin (EHB) 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.
IMPORTANT: Special procedures are required for cleaning the all-aluminum coil in this unit. See page 24 in this instruction for information.
Page 2
CUT SIZE: 6-3/4"Wide x 10-3/4" Tall
Wiring Diagrams
SYSTEM SINGLE STAGE AIR CONDITIONER TWO-STAGE AIR CONDITIONER SINGLE STAGE HEAT PUMP
TWO-STAGE HEAT PUMP
TWO-STAGE ELECTRIC HEAT TO ACTIVATE DEHUMIDIFICATION
FIELD JUMPERS NEED ALL
REMOVE Y1 TO Y2 REMOVE R TO O REMOVE Y1 TO Y2 AND R TO O REMOVE W1 TO W2 REMOVE R TO DS
WARNING
USE COPPER CONDUCTORS ONLY
PART NO. 537982-04
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
L2
L1
L2
L1 HTR 4 PRI LS
HTR 3 PRI LS
HTR 2 PRI LS
HTR 1 SEC L
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
ON OFF
ON OFF
BLK BLK
YEL
YEL
BLK
YEL
HTR 3 SEC L
L2
L1
HTR 3
L2
PRI LS
L1
7.5KW & 10KW
HTR 2
BLU
SEC L
HTR 1 SEC L
YEL BLK
RED BLK BLK YEL YEL
ON OFF
CB OR TB L1 L2
HTR2 PRI LS
HTR1 PRI LS
RED WHT
BLU
6 54 3 21
SEQ
YEL BLK
HTR 1 CB OR TB
4KW & 5KW
YEL BLK
RED BLK
YEL
12
4
18 BLUE L2
18 YEL
14 YEL
TR
COM
C
208V 240V
R 14 BLK
18 RED
18 BLUE 18 RED 18 WHITE 18 BLK 18 BLUE/WHITE 18 PRPLE 18 ORG 18 YEL
HTR 1
56
18 WHITE L2 18 BLACK L2
MOTOR
18 RED
18 BLUE
1
1 18 WHITE 2 18 WHITE 3 18 WHITE 4 18 WHITE
18 YEL
2 3 4 5 6
5 18 WHITE
1
6 18 YELLOW
2
7 18 WHITE
7 8 9
3
8 18 WHITE
10
4
9 18 ORANGE
11
5
10 18 PURPLE
11 18 WHITE
18 GRN 12 18 WHITE
12 13 14
13
15
GRD 14 15
16
18 WHITE 18 WHITE
C R W1 W2
Y2 DS O Y1
G
18 GRN
CIRCUIT BOARD
14 BLK 14 YEL(240V)
14 WHT(120V)
14 GRN
12.5KW & 15KW
HTR 2 SEC L
HTR 2 PRI LS
HTR 1 SEC L
HTR 1 PRI LS
HEATERS USED
4KW & 5 KW = HTR1 7.5 & 10 KW = HTR1 & HTR2
15 KW = 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
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 1-20 20-60
OFF 40-110 1-30
20-60 1-30
TWO 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
WIRING DIAGRAM: NO HEAT
WIRE NUTS BY OTHERS
L1
L2 OR NEUT.
15 AMP
SUPPLY VOLTAGE
12
6-PIN PLUG
GND
GND
W2
W1
G
O
R
DS
C
Y1
Y2
W2
W1
G
O
R
DS
C
Y1
Y2
14 BLK L1 14 YEL L2
Litho U.S.A.
ELECTRIC HEAT VARIABLE SPEED LABEL WIRING DIAGRAM
Supersedes
C 2011
FIGURE 1. Typical Wiring Diagram CBK45UHVT Air Handler with Electric Heat (Variable-Speed Motor) Page 3
WARNING
USE COPPER CONDUCTORS ONLY FIGURE 2. Low Voltage Connections (Variable-Speed Motor)
Page 4
BDC3 Blower Control
JP1 15 PIN PLUG (BOARD
JP1
TO MOTOR)
24V ACCESSORY CONTACTS
RATED FOR 1 AMP OR LESS
QC1
SERVICE 24V/1A QC2
OPERATIONAL SELECTOR PINS (AFFECTS BOTH
HEATING AND COOLING MODES)
NORM
4
+
3
-
2
TEST
1
ADJUST
HEAT
4 3 2 1
COOL
4 3 2 1
DELAY
CFM RUN
HEATING SPEED SELECTOR PINS
COOLING SPEED SELECTOR PINS
DIAGNOSTIC
FAN DELAY
LEDS
SELECTOR PINS
FIGURE 3. BDC3 Variable Speed Control Selections
Merit® CBK45UHVT units are equipped with a variable-speed motor that is capable of maintaining a specified CFM throughout the external static range. A particular CFM can be obtained by positioning jumpers (COOL, HEAT, and ADJUST) on the BDC3 control.
The jumpers are labeled 1, 2, 3, and 4. This indicates the selected air volume (CFM). The ADJUST jumper is labeled Test, -, +, and Norm. The - and + pin settings are used to add or subtract a percentage of the CFM selected. The Test jumper is used to operate the motor in the test mode. The delay jumper controls the timing pattern in which the fan delay occurs.
Figure 3 illustrates the BDC3 control. Use tables 2-8 to determine the correct air volume for heat and cool speed taps.
Diagnostic LEDs located on the BDC3 control to assist in servicing the unit. Read the jumper settings section before adjusting blower speed.
Adjusting the Blower Speed
Diagnostic LEDs
1 - RUN LED indicates there is a demand for the blower motor to run.
2 - CFM LED indicates the cubic feet per minute at which the unit is operating. The light flashes once for approximately every 100 CFM. For example, if the unit is operating at 1000 CFM, CFM LED will flash 10 times. If the CFM is 1150, CFM LED will flash 11 full times plus one fast or half flash.
At times, the light may appear to flicker or glow. This is normal and occurs when the control is communicating with the motor between cycles.
Move the jumper pins to select the blower speed needed to meet application CFM requirements.
JUMPER SETTINGS
IMPORTANT
Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.
Table 1 lists the recommended factory blower speed tap selections for Merit® CBK45UHVT series units. These settings are for nominal tonnage match-ups with the Merit® CBK45UHVT. When matched with other sizes, it is recommended that the CFM be adjusted to provide approximately 400 CFM per ton.
TABLE 1. Recommended Blower Speed Taps
Speed Tap Selection
Air Handler
Cooling
Heating*
Note 1 - Note 2 - Note 3 - Note 4 -
CBK45UHVT-018
COOL COOL HEAT HEAT PIN #2 PIN #2 PIN #2 PIN #2
CBK45UHVT-024
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
CBK45UHVT-030
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
CBK45UHVT-036
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
CBK45UHVT-042
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
CBK45UHVT-048
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
CBK45UHVT-060
COOL COOL HEAT HEAT PIN #3 PIN #3 PIN #3 PIN #3
NOTES 1 - Condensing Unit 2 - Heat Pump 3 - Condensing Unit with electric heat only 4 - Heat Pump with electric heat
* Minimum setting for heat
To change jumper positions, gently pull the jumper off the pins and insert it onto the desired set of pins. The following section outlines the different jumper selections available and conditions associated with each one as illustrated in figure 16.
After the CFM for each application has been determined, the jumper settings must be adjusted to reflect those given in the appropriate tables on the following pages. From the tables, determine which row of CFM volumes most closely matches the desired CFM. Once a specific row has been chosen (+, NORMAL, or -), CFM volumes from other rows cannot be used. Below are descriptions of the jumper selections.
ADJUST JUMPER
The ADJUST pins allow the motor to run at normal speed, slightly higher (approximately 10%) than normal speed, or slightly lower (approximately 10%) than normal speed.
The tables on the following pages list three rows (+, NORMAL, and -) with their respective CFM volumes. Notice in table 3, for example, that the normal adjustment setting for
Page 5
heat speed position #4 is 1000 CFM. The + adjustment setting for that position is 1080 CFM and for the - adjustment setting is 910 CFM. After the adjustment setting has been determined, choose the remaining speed jumper settings from those offered in the table in that row.
The TEST pin is available to bypass the BDC3 control and run the motor at approximately 70% to test that the motor is operational. This is beneficial primarily in troubleshooting. G must be energized for motor to run.
COOL JUMPER
The COOL jumper is used to determine the CFM during either cooling or heat pump operation without a call for electric heat. These jumper selections are activated for cooling when Y2 and DS terminals in the Merit® CBK45UHVT are energized. The are activated for heating when Y2 is energized.
Applications without the Lennox ComfortSense® 7500 thermostat will provide 70% of the COOL CFM during firststage cooling for two-stage outdoor units. 100% of COOL speed is provided for systems with a single-stage outdoor unit.
Applications with the Lennox ComfortSense® 7500 thermostat, but no demand for de-humidification will operate as follows: during a first-stage cooling call (two-stage outdoor unit), the air volume is 70% of the COOL jumper selection. This arrangement provides for additional dehumidification during standard first-stage cooling. See the tables that follow for various scenarios concerning use of the ComfortSense® 7500 thermostat and the Merit® CBK45UHVT series unit.
For applications with Harmony III® zone control, the air handler CFM volume is determined by the Harmony III control center. The minimum blower speed is predetermined at 250 CFM for -018, -024, -030 and -036 units and 450 CFM for -042, -048 and -060 units. This speed is not adjustable. See footnotes in the blower performance tables.
With the thermostat set for Continuous Fan and without a call for heating or cooling, the Merit® CBK45UHVT provides 50% of the COOL CFM selected.
NOTE - For two-stage heat pumps, air handler will operate at 70% of the COOL selection until supplemental electric heat is demanded. At that time, the air handler will operate at the selected HEAT speed. This arrangement provides warmer supply air during second-stage heating.
TABLE 2
BLOWER DATA
CBK45UHVT-018 BLOWER PERFORMANCE 0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
500 705 925 1150 365 520 665 810 500 705 925 1150
NORM
465 650 850 1050 350 485 610 740 465 650 850 1050
420 600 760 950 320 425 560 680 420 600 760 950
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 250 cfm.
TABLE 3
BLOWER DATA
CBK45UHVT-024 BLOWER PERFORMANCE
0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
450 670 900 1120 340 450 650 770 450 670 900 1120
NORM
420 620 820 1050 300 400 600 700 420 620 820 1050
390 570 750 915 280 390 500 650 390 570 750 915
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 250 cfm.
Page 6
TABLE 4
BLOWER DATA
CBK45UHVT-030 BLOWER PERFORMANCE 0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
680 885 1115 1340 490 635 770 930 680 885 1115 1340
NORM
620 810 1020 1220 440 575 715 845 620 810 1020 1220
550 725 905 1100 411 530 645 755 550 725 905 1100
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 250 cfm.
BLOWER DATA
TABLE 5
CBK45UHVT-036 BLOWER PERFORMANCE 0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
930 1155 1390 1530 640 815 970 1150 930 1155 1390 1530
NORM
830 1050 1260 1450 590 725 875 1025 830 1050 1260 1450
740 940 1135 1330 545 650 780 910 740 940 1135 1330
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 250 cfm.
TABLE 6
BLOWER DATA
CBK45UHVT-042 BLOWER PERFORMANCE
0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
1130 945 1575 1810 780 945 1110 1275 1130 945 1575 1810
NORM
1020 1255 1440 1650 710 860 1000 1160 1020 1255 1440 1650
920 1135 1300 1490 670 780 910 1040 920 1135 1300 1490
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 450 cfm.
Page 7
TABLE 7
BLOWER DATA
CBK45UHVT-048 BLOWER PERFORMANCE 0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
1375 1600 1820 2185 960 1125 1285 1620 1375 1600 1820 2185
NORM
1260 1455 1655 2085 885 1035 1185 1475 1260 1455 1655 2085
1125 1310 1490 1885 790 925 1060 1330 1125 1310 1490 1885
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 450 cfm.
TABLE 8
BLOWER DATA
CBK45UHVT-060 BLOWER PERFORMANCE
0 through 0.80 in. w.g. External Static Pressure Range
"ADJUST" Jumper Setting
"HEAT" Speed
1
2
3
4
cfm cfm cfm cfm
Jumper Speed Positions
First Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
Second Stage "COOL" Speed
1
2
3
4
cfm cfm cfm cfm
+
1600 1835 2030 2190 1110 1285 1380 1615 1600 1835 2030 2190
NORM
1465 1675 1855 2085 1000 1160 1250 1470 1465 1675 1855 2085
1320 1500 1675 1890 895 1035 1115 1320 1320 1500 1675 1890
NOTES - The effect of static pressure, filter and electric heater resistance is included in the air volumes listed. First stage cooling air volume is 70% of COOL speed setting. Continuous blower speed is approximately 50% of COOL speed setting. Lennox Harmony IIITM Zoning System applications - minimum blower speed is 450 cfm.
TABLE 9. CBK45UHVT Thermostat and Single-Stage Outdoor Unit Operating Sequence
Operating Sequence
System Demand
System Condition
Step
Thermostat Demand Y1 Y2 O G W1 W2
Relative Humidity
Status
D
NO CALL FOR DEHUMIDIFICATION
pressor
System Response
Air
Handler CFM
(COOL)
Comments
Normal Operation
1 On
On On
Acceptable 24 VAC High
100% low thermostat demand
BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation
Dehumidification Call
1 On 2 On
On On On On
Acceptable 24 VAC Demand 0 VAC
High High
100%
60%/65 70%*
gizes D on a call for dehumidification
PRECISION MODE (operates independent of a Y1 thermostat demand)
Normal Operation
1 On
On On
Acceptable 24 VAC High
100%
Dehumidification Call
2 On
On On
Demand
0 VAC
High
60%/65% midity is greater than set point 70%*
Dehumidification Call ONLY
1 On
On On
Demand
Jumpers at indoor unit with a single stage outdoor unit With Condensing unit - Y1 to Y2 and R to O With Heat Pump - Y1 to Y2
0 VAC
High
60%/65%
70%*
midity setpoint by allowing the room
mostat setpoint**
* During dehumidification, cooling air handler speed is as follows: 70% of COOL cfm for 018, 024, 030; 65% for 036; 60% for 042, 048 and 060 units. ** Thermostat will maintain the room temperature up to 2°F (1.2°C) cooler than the room thermostat setting in precision mode.
Page 8
TABLE 10. CBK45UHVT Thermostat and Two-Stage Outdoor Unit Operating Sequence
Operating Sequence
System Demand
System Response
Thermostat Demand
System Condition
Step Y1 Y2 O G W1 W2
NO CALL FOR DEHUMIDIFICATION
Relative Humidity
Status
D
pressor
Air
Handler CFM
(COOL)
Comments
Normal Operation - Y1
Normal Operation - Y2
1 On
On On
2 On On On On
Acceptable 24 VAC Acceptable 24 VAC
Low High
70% 100%
Compressor and indoor air handler follow thermostat demand
Room Thermostat Calls for First-Stage Cooling
BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation
1 On
On On
Acceptable 24 VAC
Low
70%
Dehumidification Call
2 On On On On
Demand 24 VAC
High
60%/65% 70%*
gizes D on a call for dehumidification
PRECISION MODE (operates independent of a Y1 thermostat demand)
Normal Operation
1 On
On On
Acceptable 24 VAC
Low
70%
Dehumidification Call
2 On On On On
Demand
0 VAC
High
60%/65% 70%*
midity is greater than set point
Dehumidification Call ONLY
1 On On On On
Demand
0 VAC
High
60%/65% 70%*
midity setpoint by allowing the room stat setpoint**
Room Thermostat Calls for First- and Second-Stage Cooling
BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation
1 On On On On
Acceptable 24 VAC
High
100%
Dehumidification Call
2 On On On On
Demand
0 VAC
High
60%/65% 70%*
gizes D on a call for dehumidification
PRECISION MODE (operates independent of a Y1 thermostat demand)
Normal Operation
1 On On On On
Acceptable 24 VAC
High
100%
Dehumidification Call
2 On On On On
Demand
0 VAC
High
60%/65% 70%*
midity is greater than set point
Dehumidification Call ONLY
1 On On On On
Demand
Jumpers at indoor unit with a two-stage outdoor unit With Condensing unit - Y2 and R to O With Heat Pump - none
0 VAC
High
60%/65% 70%*
midity setpoint by allowing the room stat setpoint**
* During dehumidification, cooling air handler speed is as follows: 70% of COOL cfm for 018, 024, 030; 65% for 036; 60% for 042, 048 and 060 units. ** Thermostat will maintain the room temperature up to 2°F (1.2°C) cooler than the room thermostat setting in precision mode.
HEAT JUMPER
The HEAT jumper is used to determine CFM during electric heat operation only. These jumper selections are activated only when W1 is energized.
DELAY JUMPER
The DELAY jumper is used to set the specific motor fan operation during cooling mode. Depending on the application, one of four options may be chosen by moving the jumper to the appropriate set of pins.
#1 Pins Jumpered
A- Motor runs at 100% until demand is satisfied.
B- Once demand is met, motor ramps down to stop.
A
B
OFF
100% CFM
COOLING DEMAND
OFF
#2 Pins Jumpered
A- Motor runs at 100% until demand is satisfied.
B- Once demand is met, motor runs at 100% for 45 seconds.
C- Motor ramps down to stop.
OFF
A
B
C
100% CFM
100% CFM (60 seconds)
COOLING DEMAND
OFF
#3 Pins Jumpered A- Motor runs at 82% for approximately 7-1/2 minutes. If
demand has not been satisfied after 7-1/2 minutes.
B- Motor runs at 100% until demand is satisfied. C- Once demand is met, motor ramps down to stop.
A OFF
B
7 1/2 MIN 82%CFM
100% CFM
COOLING DEMAND
C OFF
#4 Pins Jumpered
A- Motor ramps up to 82%.
B- Motor then runs at 82% for approximately 7-1/2 minutes. If demand has not been satisfied after 7-1/2 minutes,
Page 9
C- Motor runs at 100% until demand is satisfied. D- Once demand is met, motor ramps down to stop.
A OFF
B
7 1/2 MIN 82% CFM
C
100% CFM
D OFF
COOLING DEMAND
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.
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
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.
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.
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 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 tables 1 through 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 for the corresponding locations.
Page 10
· 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.
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.
FIGURE 5. Control Panel Relocated to End Panel (Right-Hand Horizontal Configuration)
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 2 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
FIGURE 4. Electrical Connections (Upflow Configuration)
NOTE - To avoid the possibility of moisture damage to the control in some right-hand discharge configurations, relocate control bracket to the pre-drilled holes in the top panel as shown in figure 5.
240 Volts 208 Volts
FIGURE 6. Converting Unit from 240VAC to 208VAC
Page 11
Requirements
IMPORTANT
CBK45UHVT 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 CBK45UHVT Product Specification bulletin (EHB).
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
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.
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.
Page 12
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)
VOLTAGE 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)
VOLTAGE INLETS
(Top and Right Side)
VOLTAGE INLETS
(Either Side)
22 (559)
AIR FLOW
A
PIPING PLATE
CONDENSATE DRAIN PIPING PLATE (3) (2-1/4 x 3-3/4)
FILTER ACCESS
SUCTION LINE
LIQUID LINE
1-1/8 (29)
D OPENING
1-1/8 (29)
1/2
20-3/8
(13)
(518)
OPENING
FRONT VIEW
SIDE VIEW
NOTE Unit is shipped configured for horizontal right-hand air discharge. Unit may be converted to horizontal left-hand air discharge by repositioning horizontal drain pan.
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
048
in.
mm
55
1397
21-1/2 546
19-1/2 495
19-1/4 489
1-1/8 (29)
060
in.
mm
59-3/4 1518
21-1/2 546
19-1/2 495
19-1/4 489
Page 13
Unit Dimensions Horiz.
DETAIL OF PIPING PLATE
CONDENSATE
CONDENSATE DRAINS (2)
4-3/4 (121)
DRAINS (2) (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)
1-1/8 (29)
22 (559)
20-3/8 (518)
OPENING
VOLTAGE INLETS (Top and Right Side)
VOLTAGE INLETS (Either Side)
1/2 (13) SUCTION LIQUID
TOP VIEW
LINE
LINE
VOLTAGE
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)
VOLTAGE 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
048
in.
mm
55
1397
21-1/2 546
19-1/2 495
19-1/4 489
060
in.
mm
59-3/4 1518
21-1/2 546
19-1/2 495
19-1/4 489
Page 14
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 CBK45UHVT 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 thru -060 models
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
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.
REFRIGERANT METERING DEVICE
CBK45UHVT 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.
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 7. 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 13).
4 - The horizontal configuration is shown in figure 8.
Drains
AIR FLOW
RIGHT-HAND DRAINS
PLUGS
FIGURE 8. Right-Hand Discharge Configuration
Page 15
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 9. Use sheet metal screws to connect the return and supply air plenums as required.
CABINET SUPPORT
TOP CAP ROTATED TO CORRECT POSITION
TOP CAP SCREWS
90º BEND
ANGLE IRON OR SHEET METAL MAXIMUM 1/2"
LONG SCREW
E ANCE 4 IN. (102 MM)
DRAIN PAN REINSTALLED
HERE
DRAIN PAN
SHIPPING LOCATION
AIR FLOW
FRONT VIEW
END VIEW
FIGURE 9. 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.
-------- 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 10. 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 10.
FRONT EDGE OF HORIZONTAL DRAIN PAN
FIGURE 11. Left-Hand Discharge Configuration
Page 16
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 Seal around the exiting drain pipe, liquid and suction lines to prevent infiltration of humid air.
9 - Flip access door and replace it on the unit.
10 - 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.
11 - 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 9. 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 -060) 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 CBK45UHVT unit in a downflow application, the circuit breakers must be rotated 180° to the UP position. See ECB45 installation instructions for more details.
Page 17
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
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). 1 LENNOX P-TRAP 49P66 REQUIRES A LARGER INSTALLATION SPACE THAN THE J-TRAP 91P90.
LENNOX1 P-TRAP 49P66, J-TRAP # 91P90 OR ANY PVC SCH 40 P- OR
J-TRAP 3/4"
2" (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)
FIGURE 12. 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.
SLOPING THE UNIT Make sure the unit is sloped (similar to the slope shown in figure 13) so that the drain pan will empty completely without water standing in the pan.
THIS CORNER SHOULD BE 5/8" (+/- 1/8") HIGHER THAN DRAIN CORNER
DRAIN CORNER
LEVEL PLANE
FIGURE 13. Sloping the Unit for Proper Drainage Page 18
INSTALL CONDENSATE DRAIN The air handler is provided with 3/4" NPT condensate drain connections.
IMPORTANT
On some pans, the primary and secondary drain holes have knockouts.
Confirm primary and secondary drains are open.
1 - CBK45UHVT 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 14. 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 36 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 12). 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 fig-
ure 6. 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 11 lists the filter size for each unit.
TABLE 11. Unit Air Filter Size Chart
CBK45UHVT
Filter Size In.
-018, -024, -030
15" x 20" x 1"
-036, -042, -048, -060
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 19
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, -048, -060
"A"
18-3/8"
21-1/2"
BOTTOM OF CABINET DUCT ADAPTER 3/4 (19)
1-1/2 (38)
FIGURE 15. Cabinet and Duct Flange
Brazing Refrigerant Lines
For R454B refrigerant installations, do not braze the line set to the evaporator coil until the outdoor unit is installed. Refer to R454B Air Handler Conversion Kit (27J27) Instructions for installation details.
Refrigerant lines must be connected by a qualified technician in accordance with established procedures.
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).
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.
Page 20
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 10.
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
Page 21
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 16. Brazing Connections
Page 22
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.
Nameplate Marking
Prior to installing the front panel, mark the unit nameplate to permanently identify the refrigerant configuration. Nameplate example shown in figure 17 below.
FIGURE 17. Nameplate Marking
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 (approximate-
ly 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.
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 23
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.
1. CUT INSULATION IN X PATTERN 2. APPLY GLUE 3. PRESS GLUED TABS AGAINST CABINET
FIGURE 18. Repairing Insulation
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 (heat pumps) 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.
· If refrigerant leak detection sensor kit (R454B applications only) has been installed, ensure that sensor opening is clear and free of debris. Follow sensor maintenance recommendations as outlined in sensor kit instruction.
Page 24
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.
Page 25
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 19. Start-up and Performance Checklist (Upflow Configuration)
Page 26
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 20. Start-Up and Performance Checklist (Horizontal Configuration)
Page 27
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